v. 1.

01

SYNCHRONOUS ALTERNATOR
Qatar 3
Serial number

601721

Type
Power
Voltage
Power factor
Frequency
Speed

LSA60 M120
20000 kVA
11000 V
0,8
50 Hz
1500 rpm

ALTERNATORS
Service & Operating Manual

LEROY SOMER

Service & Operating Manual

SECTION 0

ALTERNATORS
CONTENTS

FOREWORD

WARNING
THIS INSTALLATION AND MAINTENANCE MANUAL
CONCERNS A COMPLETE RANGE OF MACHINES.
SECTION 1 OF THIS MANUAL "DATA SHEET "
ENABLES YOU TO IDENTIFY THE CONSTITUTIVE
ELEMENTS OF YOUR PARTICULAR MACHINE

LEROY SOMER

Service & Operating Manual

ALTERNATORS
CONTENTS

VOLUME CONTENTS

SECTION 0

VOLUME CONTENTS
WARNING

SECTION 1

Generator Data Sheet

Spare Parts List

SECTION 2

TEST REPORT
(AVR Settings)

SECTION 3

Service & Operating Manual

SECTION 4

Automatic Voltage Regulator

SECTION 5

Drawings
Dedicated manuals for specific equipement

SECTION 0

LEROY SOMER

Service & Operating Manual

ALTERNATORS
Generator Data Sheet

SECTION 1

Generator Data Sheet

Spare Parts List

SECTION 1

LEROY SOMER

Service and Operating Manual

Generator unit

TABLE OF CONTENTS

1. MACHINE TECHNICAL DATA

1.1 General characteristics
1.2 Excitation - Regulation
1.3 Stator protections
1.4 Rotor Protections
1.5 Not applicable
1.6 Sleeve bearing technical data
1.7 Drive end bearing Protection
1.8 Non drive end bearing Protection
1.9 Oil circulating system
1.10 Not applicable

2. SPARE PARTS
2.1 To order spare parts
2.2 Recommanded spare parts

SECTION 1

LEROY SOMER

Service and Operating Manual

Generator unit
1. MACHINE TECHNICAL DATA
1.1 General characteristics
Project
Type
Serial Nr
Synchronous
Connections
Rated output
Voltage
Frequency
Power Factor
Polarity
Speed
Machine protection
Terminal box protection
Insulation
Temperatue rise
Generator air gap
Exciter air gap
Ambient temperature
Cooling
Weight of rotor
Total weight

Qatar 2
LSA60 M120
601721
Triphased
Star
20000
11000
50
0.8
4p
1500
IP21
IP 55
H
F
18
2
40
IC0A1
12305
35100

1.2 Excitation - Regulation

Excitation
AVR type

Brushless
AREP

1.3 Stator protections

Space heater (W)
under(V)
Stator winding sensor
Stator air outlet temperature sensor
Stator air outlet temperature sensor

2000
230
6 x Pt100
1x Pt100
1x Pt100

1.4 Rotor Protections

Earthing

Gaz turbine drive

KVA
V
Hz

RPM

mm
mm
C
Kg
Kg

SECTION 1

LEROY SOMER

SECTION 1

Service and Operating Manual

Generator unit
1.6 Sleeve bearing technical data

Type
Seal type
Seal type
Cooling / Lubrication (*1)
Axial clearance, bearing type
Axial clearance (mm)
Diametral clearance (mm)
Oil type
losses (kW)
Oil sump capacity (l)
Bearing shell temperature (C)
Oil film thickness (mm)
Refrigerant flow rate (l/min)
Accuracy of flow rate regulation
Inlet temperature (C)
Attitude angle (beta ; )

Rotation
Shaft displacement "X"
Shaft displacement "Y"

Drive
End side
EFZLK 22-225
Renk n 10
Renk n 10
Oil circulation (gravity return)

Non drive
End side
EFZLQ 22-225
Renk n 10
Renk n 10
Oil circulation (gravity return)

Locating
0.51
0.378
ISO VG 46
6.7
34
51.6
0.04
17
(weak) ; +0% -40%
40
37.9
Counter Clock Wise
0.09
0.07

Non locating

1.7 Drive end bearing Protection

Oil sump sensor

1x Pt100

1.8 Non drive end bearing Protection

Oil sump sensor

1x Pt100

0.378
ISO VG 46
4.9
34
56.4
0.053
9
(weak) ; +0% -40%
40
35.9
(Refer to chapter 4.3)
(Refer to chapter 4.3)

LEROY SOMER

Service and Operating Manual

Generator unit

2. SPARE PARTS
2.1 To order spare parts
1-Identify the machine Serial Number
on the name plate (eg : 71 155 513)
2- Identify the part number using the attached
drawings and give a description
2.2 Recommanded spare parts
Rotating diodes
Automatic Voltage Rgulator
Shell

6
1
1

SKN 240/12
R630
E.ZLK 22-225

SECTION 1

Moteurs Leroy Somer

Dept. ACEO
Boulevard Marie Stuart
45005 ORLEANS CEDEX01 - FRANCE

Tel. :
Fax:

+33 (0)2 38 60 42 27
+33 (0)2 38 60 42 85
C.Kouroghli

Date:
Customer:
Project:
LS Reference:

Subject:
Site:
Application:

UAE
Production

Prime mover:
Manufacturer:
Type:

18-sept-07
Turbomach
Qatar 2
601721

3
1
3
1

V2007/3a
Gas turbine
Solar
Titan 130

1
1
1

Main data:
Generator type:
Power:
Voltage:
Speed:
Frequency:
Power factor:
Winding pitch:
Insulation:
Temperature rise:
Ambient:
Altitude:
Protection:
Cooling:
Cooler:

LSA 60 M120 / 4p
20 000 kVA
11000 V
1500
rpm
50
Hz
0,8
p5/6
Stator:
Stator:
40
C
1000
m
IP21
IC0A1
Coolant:

16 000 kWe
Star connection
Overspeed:
Nominal curent:

H
F

Rotor:
Rotor:
Quality:

1800
1 050 A

H
F
Clean air

Filter:
Without filters
Ventilation:
Self vent.
Temperature C:
40

Air

16 337 kWm
5%
Duration (min.):

Exciter:
Exciter:

H
F

Piping:

No

1
1
1
1
1
1
1
1
1
1
1
1
1
1

Connection & regulation:

Number of wires:
Neutral point:
Parallel operation:
Type of excitation:
AVR type:
Voltage sensing:
Manual voltage:
4-20 mA card:
Voltage potentiometer:
PF potentiometer:
Radio int. suppression:

6 wires
Isolated neutral
Sustained short circuit :
With mains (3F)
Catalogue schematic:
Shunt with booster and PMI
R630
For panel mounting
Terminal box mounted voltage sensing VTs
No
No
Digital voltage potentiometer
Digital power factor potentiometer
Class N

greater than 3 x FLC for 10 seconds

LS Supply
LS Supply

1
1
1
1
1
1
1
1
1
1
1

Electrical data:
Efficiency:
Power factor 0,8
Power factor 1,0:
Reactances and
time constants:
SCR:
0,48

110%
98,0 %
98,4 %
Xd
226

Xq
136

100%
97,9 %
98,3 %

75%
97,7 %
98,0 %

X'd
X"d
X"q
X2
30,4
21,7
27,1
24,4
Unsaturated, (rated KVA): %

50%
97,1 %
97,3 %
Xo
15,2

T'do
8,76

25%
94,9 %
95,0 %
T'd
T"d
1,18
0,050
Seconds:

1
1
Ta
0,277

1
1

Mechanical data:
Mounting:
IM1101
Bearing type:
Oil circulating sleeve bearing
Shaft end:
Standard bare keywayed
Bearing insulation:
1 bearing insulated
Balancing:
Full key
Rotation:
Counter clockwise (seen when facing the D-end)
Shaft height:
mm
1000
Width:
mm
1950
Axial clearance
mm
Standard
External load on shaft end (daN)
No
Requested inertia (MR2 / kgm2)
No

Two bearing, horizontal

Flange:

None / without

1
1
1
1
1
1
1
1
1
1
1

Protection:
Winding sensors:
6 x PT100
Bearing sensors:
1 X PT100 per bearing
Anti-condensation heater: Yes
Voltage:
230 V
Air sensor:
1 x PT100 sensor on air outlet 1 x PT100 sensor on air inlet
Class
Power (VA)
Current measuring CTs: Quantity
LS supply
Line side
LS supply
3
0,5M5
20
Neutral side
6
5P10
20
Class
Power (VA)
Voltage measuring VTs: Quantity
LS supply
3
3P
30
Line side
6
1
30
LS supply
Neutral side
Rotor protection:
Rotor earthing brush
None
Speed measurement:
None
Diode failure detector:
None
Water leakage detector:
None
Braking system:
None
Fire estinguisher:
None
Vibration sensors:
None
Jacking device:
0
0
Lube oil pump:
None
Oil level detector:
None

1
1
1
1

Power:
I Primary (A)

1200
1200
U Primary (V)
6351
6351

I Secondary (A)

5
5
U Secondary (V)
36,7
63,5

1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

Terminal box:
Number of wires:
Cable glands:
Line side outlet:
Gland plate:
Protection:
Type of box:
Extension box:

4 wires
None
Refer to comments
Non magnetic
Standard
Standard
None

1
1
1
1
1
1
1

Set of spare parts:

Rotating diodes:
Voltage regulator:
AVR cards:
DE sleeve:
NDE sleeve:
Roller bearing (1 set):

Filter (1 set):
No
No
No
No
No
No

No

1
1
1
1
1
1
1

Controls:
Rule:
Quality plan:
QUAL/INES/006 001
QUAL/INES/006 021
QUAL/INES/006 002
QUAL/INES/006 003
QUAL/INES/006 004
QUAL/INES/006 005
QUAL/INES/006 007
QUAL/INES/006 008
QUAL/INES/006 009
QUAL/INES/006 010

CEI
None
Measurement of winding resistance
Insulation check on sensors (when fitted)
Voltage balance and phase order check
No load characteristics, no load losses
Three phase short circuit characteristic
On load test
Overspeed test
Calculation of efficiency by summation of losses
High potential test
Insulation resistance measurement

QUAL/INES/006 019

Measurement of specified vibration level

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

Documentation:
Number of manuals:
Language:

1
Anglais

1
1

<2,8 mm/s RMS

G1

1
1
1
1

Various items:
Reduced vibration level:
balancing class:
Requested noise level:
Paint:

SC1 RAL 7032

Performances:
Voltage accuracy:
0,5%
Maximum inrush current for a voltage dip of 15 %:
12900 kVA
when starting an AC motor having a starting power factor between 0 and 0.4

Comments:
Regulation:
Excitation AREP

1
1

Mechanical aspects:
1
1
Protection and measurement:
prvoir paliers lisses pr-quips pour soulvement hydrostatique

1
1

Sortie des cables par l'arrire

ralisation BaB spciale sur toute longueur machine av E/S air au dessus des entretoises

1
1

Terminal box:

Spare parts:
1
1
Special requirements:
1
1

LSA 60 M120 / 4p - 20000 kVA - 11000 V - 1500 rpm

Efficiency curves.
99

Efficiency - Rendement en %

98

97

96

95
PF 1

0,8

94

93
25%

50%

75%

100%

Load - Charge - % of rated electrical kW

Transient voltage dip curve at 0,8 P.F. load impact

30%

Voltage dip - Chute de tension

25%

20%

15%

10%

5%

0%
0,0

0,4

0,8

1,2

Inrush - Appel de charge - I (per unit)

1,6

2,0

Inrush - Appel de charge - I (per unit)

LSA 60 M120 / 4p - 20000 kVA - 11000 V - 1500 rpm

Capability Curve.
0,8 p.f.

0,9 p.f.

0,7 p.f.

0,9 p.f.

0,8 p.f.
0,7 p.f.

1
KW / rated KVA
0,9
0,8

0,6 p.f.

0,6 p.f.
0,7
0,6

0,5 p.f.

0,5 p.f.

0,5
0,4 p.f.

Shunt + Booster
with R449

0,4 p.f.
0,4

0,3 p.f.
Shunt / PMG / AREP
Shunt + Booster with R600

0,2 p.f.

0,3

0,3 p.f.

0,2

0,2 p.f.

0,1

0,1 p.f.

0,1 p.f.

KVAR / rated KVA

0
-1

-0,8

-0,6

-0,4

-0,2

0,2

0,4

0,6

0,8

Stator current decrement curves.

7
Isc (Per unit - rms)

Heat damage curve

Short-circuit at generator terminals

Symmetrical phase to neutral short circuit

Symmetrical two phase short circuit

Symmetrical three phase short circuit

0
0,001

0,01

0,1

10

100
Time (sec)

LEROY SOMER

Service & Operating Manual

ALTERNATORS
TEST REPORT

SECTION 2

TEST REPORT
(AVR Settings)

SECTION 2

Ateliers de Constructions Electriques d'Orlans

Configuration of AVR and

Settings of Potentiometers

ACEO
Order

Test date

04/09/2007

60 M120

Order

601721/2

Mains I/O
Serial N
P1

C51950220F
07180956
4

Cos /kVAR
Serial N
P1
P2
P3
P4
P5
P6
P7
Select of droop

C51950081F
07242177
5
5
6
2,5
2,8
0
3
-

Digital settings
Serial N
P1
P2
P3
Jump U - SW1
Jump Cos -SW2
Jump SW3 - SW4

C51950111F
07251126
5
4
6
+/+/Ouvert

Aux I/O CARD

P.F.
Serial N
P1
P2
P3
P4
P5
P6
P7
way 1
Jump way 1
CV1-CV3
CV5
way 2
Jump way 2
CV2-CV4
CV6

Manual mode
Serial N
P1
P2
P3
P4

C51950101G

Iexc Digital settings

Serial N
P1
P2
P3
Jump 1 - Ref or U/F
Jump 3-4 - Follo or Not

C51950141F

Customer

Turbomach

Type of AVR

R630

Type of Generator

Rack
Serial N

C51950284A
862

Power Block
Serial N

C51950303F
03440378

Generator I/O
Serial N
Jump of select U
Jump of select TP3

C51950200G
07391293
110V
120V

Rack supply
Serial N

C51950041G
07243102

Dtection Sensing
Serial N
P1
P2
P3
P4
P5
CV1

C51950051G
07242983
5
5
6
0
4,5
U/F

PID
Serial N
P1
P2
P3
P4
P5
P6
P7
P8
ST1
ST2

C51950061I
07242113
6,5
5
2
3
2,5
5
2
10
vers C4
inactif

Driver
Serial N
P1
P2
P3
P4
P5
P6
P7
P8

C51950071G
07243068
10
5
5
1,2
7 (1 volt)
4
6
10

LEM
Serial N
Captor Hall

C51950076F
03411739
2

C51950121H

Limit I stator
Serial N
P1
P2
P3
P4

5
Ref
Follower

Repere of
potentiometer
9

Tested by :

M.Bena
ELEC/FCTL/000 009

16/10/2007

LEROY SOMER

Service & Operating Manual

ALTERNATORS
Service & Operating Manual

SECTION 3

Service & Operating Manual

SECTION 3

2327 en 02.2006 / k

ALTERNATOR
Service & Operating Manual

LEROY SOMER

SERVICE AND OPERATING MANUAL

2327 en 02.2006 / k

ALTERNATORS

TABLE OF CONTENTS
2.3.3 Maintenance of antifriction bearings

1. GENERAL INFORMATION
1.1 INTRODUCTION
1.1.0 General points
1.1.1 Safety notes
1.1.2 Conditions of use
a) Generalities
b) Vibratory analysis

1.2 GENERAL DESCRIPTION

1.2.1 Generator
1.2.2 Excitation system

2. DESCRIPTION OF SUB-ASSEMBLIES
2.1 STATOR
2.1.1 Electric machine armature
a) Mechanical description

2.1.2 Excitation field winding

2.1.3 Stator protection
a) Heating resistor
b) Stator winding temperature sensor
c) Stator air sensor
d) Stator vibration sensor

a) General points
b) Lubricant
c) Cleaning bearings

2.3.4 Servicing the antifriction bearings

a) General points
b) Removing the bearings
c) Bearing reassembly

2.3.5 Antifriction bearing protection devices

2.3.9 Antifriction bearing installation drawing

2.4 SLEEVE BEARINGS (Plain)

2.4.0 Description of horizontal Sleeve bearings
a) Physical description
b) Operating description of Self-lubricating bearing
c) Operating description of Oil circulation bearing

2.4.1 Electrical insulation of Sleeve bearings

a) Illustration diagram of the insulating film
b) Insulation check

2.4.2 Storage of Sleeve bearings machine

a) General points
b) Short term storage
c) Long term storage

2.4.3 Oil circulation installation

a) General
b) Supply line
c) gravity oil return

2.4.4 Start-up of Sleeve bearings

2.2 ROTOR
2.2.1 Revolving field-coil
2.2.2 Excitation armature
2.2.3 Fan (machines: IC 0 A1)
2.2.4 Rotating diode bridge
a) General points
b) Tightening torque for the rotating diode
fastening screws
c) Rotating rectifier test

2.2.5 Balancing

2.3 ANTI FRICTION-BEARINGS

(rolling bearing)
2.3.0 Description of antifriction bearings
2.3.1 Start-up of antifriction bearings
2.3.2 Storage of machine with anti friction
bearings

a) General check before start up

b) Self-lubricating bearings start up data
c) Water cooled bearing (type EFW..) start up data
d) Oil circulation bearing with non-accurate oil flow
(+0% ; -40%)
e) Oil circulation bearing with accurate oil flow
(+5% ; -10%)
f) Inspection of Sleeve bearings at the end of startup

2.4.5 Maintenance of Sleeve bearings

a) Verification of oil-level
b) Temperature verification
c) Oil draining
d) Pressure measurement of a Sleeve bearing
housing
e) Oil for sleeve bearing
f) Oil sump capacity
g) Sealing Compound

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SERVICE AND OPERATING MANUAL

2327 en 02.2006 / k

ALTERNATORS
2.4.6 Dismantling
a) Tools and equipment
b) Lifting equipment
c) Dismantling of the shaft seal type 10 (outboard
side)
d) Dismantling of the shaft seal type 20 (outboard
side)
e) Dismantling of the top half of the housing
f) Removal of the top half of the shell
g) Dismantling of the loose oil ring
h) Dismantling the machine side shaft seal
i) Removal of the bottom half of the shell
j) Dismantling of the machine seal

2.4.7 Cleaning and checking

a) Cleaning
b) Wear checking
c) Insulation checking (only for insulated bearing)

2.4.8 Assembly of the Bearing

a) Fitting in the bottom half of the shell
b) Assembly of the shaft seal machine-side
c) Installation of the loose oil ring
d) Fitting in the top half of the shell
e) Closing of the bearing
f) Assembly of the type 10 Outboard Side Seals
g) Assembly of the type 20 Outboard Side Seals
h) Assembly of the RD-thrust pads ; bearing type
E...A

2.8.1 Cleaning
a) Air filter cleaning period
b) Air filter cleaning procedure

2.18 TERMINAL BOX

2.18.0 Description
2.18.1 Electric panel
a) Compounding panel ( if compound regulator)
b) Booster plate ( if shunt regulator)

2.18.2 Automatic voltage regulator

2.18.3 Electrical contact tightening

2.19 PROTECTION DEVICES

2.19.1 Stator protection devices
2.19.2 Bearing protection devices
2.19.3 Cooler protection devices

2.20 NAMEPLATES
2.20.1 Main nameplate
2.20.2 Lubrication nameplate
2.20.3 Rotation direction nameplate

3. VOLTAGE REGULATOR AND EXTERNAL

AUXILIARIES

2.4.9 Oil-leakage trouble-shooting

a) Self-lubricating bearing
b) Oil circulation bearing

2.4.10 Sleeve bearing protection devices

a) Sight-level glass
b) Oil thermometer
c) Thermostat or sensor
d) Pre lub pump

2.7 COOLER
2.7.0 Description of the cooler
a) General points
b) Description of AIR-AIR coolers
c) Description of AIR-WATER DOUBLE TUBE
EXCHANGER
d) Description of AIR / WATER SINGLE TUBE
EXCHANGER

4. INSTALLATION
4.1 STORAGE
4.1.1 Storage warehouse
4.1.2 Maritime packing
4.1.3 Unpacking and installation
4.1.4 Storage measures of a site machine

4.2 INSTALLATION OF THE ELECTRIC

MACHINE
4.2.1 Fitting the coupling (double-bearing
machine only)
4.2.2 Fitting the stator

2.7.1 Start-up of the cooler

a) General points

2.7.2 Maintenance of the water-cooler

a) General points
b) Cleaning
c) Leak detection for a double-tube exchanger

2.7.3 Servicing the water-cooler

a) Cooler removal
b) Cooler re-assembly

2.7.4 Cooler protection devices

a) Leak detection (float system)
b) Water temperature sensor

2.8 AIR FILTERS

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SERVICE AND OPERATING MANUAL

2327 en 02.2006 / k

ALTERNATORS
4.3 ELECTRIC MACHINE ALIGNMENT
4.3.1 Various alignment characteristics
a) General points
b) Axis height Thermal elevation
c) Sleeve bearing shaft elevation
d) Antifriction bearing shaft elevation

5.2 MECHANICAL START-UP INSPECTION

5.2.0 General points
a) Alignment; fixing; prime mover
b) Cooling
c) Lubrication

5.2.1 Vibrations

4.3.2 Two bearings machine alignment

a) machines without axial end play (standard)
b) machines with axial end play

4.3.3 Single bearing machine alignment

a) General points
b) Single bearing machine except A56 equipped
with anti friction bearing
c) Single bearing machine A56 Anti frictionbearing, only

4.3.4 Alignment procedure

a) Checking "Double concentricity" alignment
method

4.4 ELECTRICAL CONNECTIONS

4.4.0 General points
4.4.1 Phase-sequence
a) standard machine.IEC 34-8
b) if wanted, NEMA.

4.4.2 Insulating distances

4.4.3 Added products in the terminal box

5. START-UP
5.0 START-UP SEQUENCE
5.0.1 Static checks
5.0.2 Rotating checks
a) Rotating checks not excited
b) Rotating checks at no load excited
c) Generator and site safeties
d) Rotating checks at full load

5.0.3 Generator Start Up check list

5.1 ELECTRICAL START-UP INSPECTION

5.1.0 General points
5.1.1 Windings Insulation
5.1.2 Electrical connections
5.1.3 Parallel operation
a) Definition of parallel operation
b) Possibility of parallel operation
c) Parallel coupling

6. PREVENTIVE MAINTENANCE
6.1 MAINTENANCE SCHEDULE
6.2 MECHANICAL MAINTENANCE
6.2.1 Air gap check
a) Double bearing machine
b) Single bearing machine

6.2.2 Bolts tightening

6.2.3 Cleanliness

6.3 ELECTRICAL MAINTENANCE

6.3.1 Measuring instruments
a) Instruments used
b) Identification of ohmmeter polarity

6.3.2 Insulation check of the winding

a) General
b) Armature insulation measure
c) Field insulation measurement
d) Exciter insulation measurement
e) Polarisation index

7. SERVICING
7.1 GENERAL SERVICING
7.2 TROUBLE SHOOTING
7.2.0 General points
7.2.1 Regulator trouble-shooting procedure

7.3 ELECTRICAL TESTS

7.3.1 Stator winding test
7.3.2 Rotor winding test
7.3.3 Excitation armature winding test
7.3.4 Excitation field winding test
7.3.5 Rotating diode bridge test
7.3.6 Electric panel test

LEROY SOMER

SERVICE AND OPERATING MANUAL

2327 en 02.2006 / k

ALTERNATORS
7.4 CLEANING THE WINDINGS
7.4.0 General points
7.4.1 Coil-cleaning product
a) general
b) Cleaning products

7.4.2 Cleaning the stator, rotor, excitation and

diodes
a) using specific chemical product
b) Rinsing using soft water

7.5 DRYING THE WINDING

7.5.0 General points
7.5.1 Drying method
a) General points
b) Drying generator stop
c) Drying generator in rotation

7.6 RE-VARNISHING
10. FOLDOUT

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ALTERNATORS
1. GENERAL INFORMATION

1.1.2 Conditions of use

1.1 INTRODUCTION

a) Generalities
A machine must only be installed, operated, by specifically
trained persons.

1.1.0 General points

This manual provides installation, operating and
maintenance instructions for synchronous machines. It also
describes the basic construction of these machines. This
manual is general ; it applies to an entire group of
synchronous generators. Additionally, in order to make
information-finding easier, Section 1, "Characteristics and
Performance", has been included, describing the machine
completely (type of construction, type of bearing, protection
index, and so forth...); this will enable you to determine
exactly the chapters which apply to your machine.
This synchronous machine has been designed for a
maximum length of service. To achieve this, it is necessary
to pay special attention to the chapter concerning the
periodic maintenance schedule for the machines.
1.1.1 Safety notes
The warnings "DANGER, CAUTION, NOTE" are used to
draw the users attention to different points:
DANGER :
THIS WARNING IS USED WHEN AN OPERATION,
PROCEDURE, OR USE MAY CAUSE PERSONAL
INJURY OR LOSS OF LIFE
CAUTION :
THIS WARNING IS USED WHEN AN OPERATION,
PROCEDURE, OR USE MAY CAUSE DAMAGE TO OR
DESTRUCTION OF EQUIPMENT
NOTE :
This warning is used when an operation, procedure, or
delicate installation requires clarification.

Any technical engineer who operate, maintain this machine

must be allowed to practice in regard with local working
laws (eg: to be certified to operate on high voltage devices
)
A machine can only be operated for the duty foreseen by its
original tender.
The main data of this machine are summarized in "Section
1" of this manual
Any operating condition other than those specified by the
original tender must receive a Leroy Somer agreement
Any modification of the machine structure must receive a
Leroy Somer agreement
b) Vibratory analysis
It is the responsibility of the gen set manufacturer to ensure
that the different assembled system will be vibratory
compatible.(ISO 8528-9)
It is the responsibility of the gen set manufacturer to ensure
that the shaft line torsional analysis has been done and
accepted by the different parties (ISO 3046)
CAUTION :
EXCEEDING THE VIBRATORY LEVEL ALLOWED BY
THE STANDARD ISO 8528-9 MAY CREATE HEAVY
DAMAGES (BEARING DAMAGE, STRUCURE CRACKS
).
EXCEEDING THE TORSIONAL VIBRATORY LEVEL OF
THE SHAFT LINE (ex: ABS, LLOYD ) MAY CREATE
HEAVY DAMAGES (CRANKSHAFT FAILURE ,
GENERATOR SHAFT FAILURE, )
Refer to chapter 2.1.3 for further information about the
accepted vibration level of the standard ISO 8528-9

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1.2 GENERAL DESCRIPTION
1.2.1 Generator
The synchronous generator is an alternating-current
machine, without rings or brushes. The machine is cooled
by the flow of air through the machine.
For a batter comprehension, use the drawings of chapter
10.
1.2.2 Excitation system
The excitation system is mounted on the side opposite the
coupling.
The excitation system comprises two assemblies:
The excitation armature, generating a three-phase current,
coupled with the three-phase rectifier bridge (comprised of
six diodes) supplies the excitation current to the generator
revolving field. The excitation armature and the rectifier
bridge are mounted on the synchronous generator rotor
shaft and are interconnected electrically with the revolving
field of the machine.
The excitation field winding (stator) is supplied by the
control (in direct current)

1
3

1- Excitation field winding

2- Excitation armature
3- Rotating diode bridge
4- Revolving field
5- Machine stator

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ALTERNATORS
2. DESCRIPTION OF SUB-ASSEMBLIES
2.1 STATOR
2.1.1 Electric machine armature
a) Mechanical description
The machine stator comprises low-loss steel laminations,
assembled under pressure. The steel laminations are
blocked axially by a welded ring. The stator coils are
inserted and blocked in the slots, then impregnated with
varnish, and polymerised to ensure maximum resistance to
mould, excellent dielectric rigidity and perfect mechanical
linking.
2.1.2 Excitation field winding
The excitation field winding comprises a solid element and
a winding.
The excitation is flanged on the rear end shield of the
machine.
The winding is made of enamelled copper wires.
2.1.3 Stator protection
a) Heating resistor
The heating element avoids internal condensation during
the shutdown periods. It is connected to the main terminal
box strip. The heating resistor is switched on as soon as
the machine is shut down. It is located at the back end of
the machine.
The electrical characteristics are provided in Section 1
"Technical Characteristics".

To improve the machine protection the alarm set point may

be reduced following effective site information:
Alarm temperature (*) = Highest recorded temp + 10K
Trip temperature (*) = Alarm temperature + 5 K
(*) do not pass over the values of the previous chart.
(*)Highest recorded temp: Temperature measured at the
site in the worst temperature condition at the stator
temperature sensor
E.g. : a class B machine reached 110C during a factory
heat run test. Set the alarm temperature to 120C instead
of 130C as indicated in the previous chart. Set the
emergency shutdown to 115C instead of 135C as
indicated in the previous chart.
c) Stator air sensor
As an option an RTD or thermostat can measure the stator
air inlet temperature (cold air)
Stator air inlet temperature; Alarm points and shutdown:
alarm
Nominal air inlet stator + 5 K
shutdown
80C
Stator air outlet temperature; Alarm points and shutdown:
alarm
Nominal air inlet stator + 35K
shutdown
Nominal air inlet stator + 40K
NOTE :
For an open drip proof machine the nominal air
temperature entering the stator corresponds to the ambiant
temperature
Inhibit the stator air sensor safety "alarm" for few seconds
during the machine start up;
NOTE:
For a water cooled machine (CACW) the nominal air
entering the stator may be approximated as following:
Tair entering stator = Twater entering cooler + 15K

b) Stator winding temperature sensor

The temperature sensors are located in the active part of
the stack. They are located in the zone assumed to be the
hottest part of the machine. The sensors are connected to
a terminal box.
Depending on the temperature rise of the machine, the
temperature of the sensors should not exceed a maximum
of :
TEMP. RISE
class

ALARM

TRIP

Power (KVA)

< 5000

> 5000

< 5000

> 5000

130 C

125 C

135 C

130 C

150 C

145 C

155 C

150 C

170 C

170 C

175 C

175 C

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d) Stator vibration sensor
The vibration level of the machines is directly linked to the
duty and to the site characteristics.

2.2.2 Excitation armature

The excitation armature is constructed by stacking
magnetic steel laminations. These steel laminations are
held in place by rivets.

We propose the following adjustment:

The excitation coil is keyed and heat-shrunk onto the shaft.

Vibration Alarm (*) = Site Highest Vibration level + 50%

Vibration Trip = Vibration Alarm + 50%
(*) do not pass over the values of the following chart

The windings are enamelled copper wires, class "F"

insulation (or "H", depending on the customer's request or
size of the machine).

The machines are engineered to be able to withstand the

vibration level indicated by the standard ISO8528-9
Engine speed

Power

Vibration level

( RPM)

( kVA )

(mm/s ; RMS)
Engine

Generator

1300 to 2199

> 250

< 45

< 20

721

250

< 45

< 20

> 1250

< 45

< 18

> 1250

< 45

< 15

to 1299
720

< 10 (*)
(*) generator on concrete base

2.2 ROTOR
2.2.1 Revolving field-coil
The revolving field coil comprises a stack of steel
laminations, stamped and cut to reproduce the indentation
of the projecting poles.
The steel lamination stack-up is terminated at each end
with high-conductivity electrical plates.
To enable parallel operation between machines, and in
order to ensure stability, high electrical conductivity bars
are inserted in holes crossing the poles from one side to
the other. These bars are welded with the stack end
laminations in order to obtain a complete cage winding (or
LEBLANC dampening cage).

2.2.3 Fan (machines: IC 0 A1)

The synchronous machine is characterized by a selfventilation system. A centrifugal fan is mounted between
the revolving field coil and the front bearing.
Air intake is at the rear of the machine and the exhaust on
the drive end side.
The fan consists of a hub, which is keyed and heat-shrunk
onto the shaft. The flange is made of welded steel,
attached to the hub with hexagonal head-cap screws. The
ventilation effect is obtained through welded, inclined
blades. The air exhaust is effected radially.
2.2.4 Rotating diode bridge
a) General points
The rectifier bridge, comprising six diodes, is placed at the
rear of the machine. The rotating bridge is made of glass
fibre with a printed circuit to connect the diodes together.
This bridge is supplied with alternating current by the
excitation armature and supplies direct current to the
revolving field-coil. The diodes are protected against over
voltage by rotating resistors, or by varistors. These
resistors (or varistors) are mounted in parallel with the
revolving field-coil.

2
1

The winding (B) is placed around the pole (A) and is

impregnated with epoxy resin (class F machine insulation)
or with varnish (class H machine insulation).
The winding is made of insulated flattened copper with high
electrical conductivity.
The aluminium plates (E) are pressed against the winding,
acting as a heat dissipator and ensure excellent clamping
of these coils.

1 - Field
2 - Rotating resistors
3 - Exciter armature

Support bars (C) on each pole protect the end windings

against the centrifugal force.
The revolving field-coil is heated and shrunk onto the shaft.

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The inner and outer rings are connected to the revolving
field-coil

c) Rotating rectifier test

Carry out the test using a D.C. source as indicated below.
A diode in good condition should allow the current to flow
only in the anode-to-cathode direction.
Disconnect the diodes before the test.

3 ... 48 volts

+
1

1 - Outer ring
2 - Inner ring
The diode fastening screws must be tightened to the
correct torque.
b) Tightening torque for the rotating diode fastening
screws
CAUTION :
THE ROTATING DIODE FASTENING SCREWS MUST
BE TIGHTENED USING A TORQUE WRENCH
CALIBRATED TO THE RECOMMENDED TORQUE.
Diode

Tightening torque

SKR 100/..

1.5 m.daN

SKR 130/..

1.5 m.daN

SKN 240/..

3 m.daN

1 - Anode
2 - Cathode

Diode type

Positive

Negative

SKR

diode housing

diode wire

SKN

diode wire

diode housing

When reassembling ensure that the diodes are be

tightened to the correct torque
2.2.5 Balancing
The entire rotor has been balanced according to ISO8221
standard in order to obtain a residual imbalance less than :
Gen set : Class G2.5
Turbine : Class G1
The balancing is carried out at two levels. The first is that of
the fan. It is recommended, when the fan is refitted (after
servicing) to respect the initial indexing.
The second is that of the shaft end. The shaft end is coldstamped to indicate the type of balancing.
H : balancing with Half-key carried out as
standard
F : balancing with Full key
N : balancing without key (None)
The coupling must be balanced to fit the generator rotor
balancing.

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2.3 ANTI FRICTION-BEARINGS
2.3.0 Description of antifriction bearings
The bearings are installed at each end of the machine.
They can be replaced.
The bearings are protected from external dust by labyrinth
seals.
The bearings must be lubricated regularly. The old grease
is forced out at the lower part of the bearings by the force
of the new grease being injected.
2.3.1 Start-up of antifriction bearings
The bearings are pre-lubricated in the factory, but before
they are put into service, it is necessary to complete this
lubrication.
CAUTION
UPON START-UP, GREASE THE MACHINE WHILE IT IS
RUNNING SO AS TO FILL ALL THE FREE SPACES IN
THE GREASING DEVICE
Record the temperature of the bearings during the initial
operating hours. Poor lubrication can cause abnormal
heating.
If the bearing hisses, lubricate it immediately. Some
bearings may make a clattering noise if they do not operate
at normal temperature. This may occur if the weather is
very cold or when the machine is operating under abnormal
temperature conditions (start-up phase, for example). The
bearings will become quieter after having reached their
normal operating temperature.
2.3.2 Storage of machine with anti friction bearings
This chapter must be taken in consideration if a machine is
stopped more than 6 months.
Grease the bearings , machine stopped , inject two time the
grease volume used for a standard maintenance.
Every 6 months turn the the machine shaft line of few turns.
Then inject a standard grease volume

2.3.3 Maintenance of antifriction bearings

a) General points
Antifriction bearings or ball bearings do not require special
maintenance.
They must be lubricated regularly with the same type of
grease as used in the factory. For information concerning
the lubrication quantity and interval, refer to Section 1 :
"Characteristics and Performance".
CAUTION :
LUBRICATION MUST BE CARRIED OUT AT LEAST
EVERY 6 MONTHS
CAUTION :
DO NOT MIX GREASE OF DIFFERENT SOAPBASES.
WHEN CHANGING THE TYPE OF GREASE, CLEAN THE
BEARING BEFOREHAND.
NOTE :
After a regreasing the bearing temperature may increase of
10 to 20C
This temporary temperature increase may stay few tens of
hours
b) Lubricant
recommended lubricant: SKF LGWA2 or SHELL RETINAX
LX2 (lithium complex).
Criteria for an alternative grease :
Mineral oil or PAO (SHC)
Soap grad NLGI 2 or NLGI 3
Lithium soap or lithium complex
Oil kinematic viscosity 100 to 200 mm2/s
Oil separation (DIN 51817) : 2% minimum
Following lubricant may be considered as acceptable ::
BP
Energrease LS3
ELF
Rolexa 3
ESSO
Beacon 3
MOBIL
Mobilux EP3
TEXACO
Marsak Multipurpose 3
SHELL
Alvania RL3 ; RETINAX LX2
c) Cleaning bearings
This note is applicable when the type of grease is changed.
Dismantle the machine in order to get to the bearing
Remove the old grease with a palette knife.
Clean the lubricator and the grease removal tube.
For greater cleaning efficiency, use a brush with solvent.
NOTE:
The most widely-used solvent is gasoline : white spirit is
acceptable.

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ALTERNATORS
DANGER:
THE PROHIBITED SOLVENTS ARE:
CHLORINATED SOLVENT
(TRICHLORETHYLENE,TRICHLOROETHANE) WHICH
BECOMES ACID
FUEL-OIL (EVAPORATES TOO SLOWLY)
GASOLINE CONTAINING LEAD
BENZINE (TOXIC)
Blow compressed air onto the bearings to evaporate the
excess solvent.
Fill the bearing with the new grease.
Re-assemble the cage and the parts, which have been
dismantled, filling them with grease.
Use a grease pump to complete the bearing lubrication
(while machine running)
2.3.4 Servicing the antifriction bearings
a) General points

c) Bearing re-assembly
A bearing can be refitted if it is known to be in perfect
condition
Before refitting a bearing, carefully clean the surface of the
bearing and the other parts of the bearing.
To install the bearing on the shaft, it is necessary to heat
the bearing. The heat source may be an oven or a space
heater (the use of oil baths is strongly discouraged).
CAUTION:
NEVER HEAT A BEARING TO MORE THAN 125C
(257F)
Push the bearing up to the shaft shoulder, and check after
cooling that the inner ring is still in contact with the
shoulder. Lubricate using the recommended grease.
2.3.5 Antifriction bearing protection devices
As an option, the bearing may be protected from overheating by RTD or PTC sensors (customers choice)..

CAUTION:
CLEANLINESS IS IMPERATIVE

For special use in warm surroundings where the

temperature of the bearings exceeds the authorised limit
(for a bearing known to be in good condition), contact us.

b) Removing the bearings

The inner bearing race is mounted, shrunk onto the shaft.

Bearing; Alarm points and shutdown:

alarm
90C (194F)
shutdown
95C (203F)

The outer bearing race is free, or slightly tightened, on the

hub (depending on the type of bearing). To remove the
bearing from the shaft, it is necessary to use a hub-puller to
avoid damaging the surface of the bearing.

To improve the machine protection the alarm set point may

be reduced following site effective information:
Alarm temperature (*) = Highest recorded temp + 15K
(*) do not pass over the values of the previous chart.
E.g. : At site the common bearing temperature is 60C. Set
the alarm temperature to 75C instead of 90C as indicated
in the previous chart

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ALTERNATORS

2.3.9 Anti friction bearing installation drawing

Machine type A50

Drive end

Non drive end

End shield

O-Ring

End cover

Non drive end shield

Ball bearing 6226 C3

End cover

End cover fixing screw

Ball bearing 6226 C3

Bearing pre load washer

10

End cover fixing screw

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ALTERNATORS
2.3.9 Anti friction bearing installation drawing (following)
Machine type A52.2; Two bearings

Bearing assembly "Power plant"

Drive end

Non Drive end

End cover

End shield

End cover fixing screw

End cover fixing screw

Ball bearing 6232 MC3

End cover

End shield

Roller bearing NU 1028 MC3

Bearing assembly " Marine "

Drive end
1
2

Non Drive end

9

same as "power plant"

End shield

10

End cover

11

End cover fixing screw

12

Bearing pre load spring

13

Ball bearing 6226 C3

14

O-Ring

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ALTERNATORS
2.3.9 Anti friction bearing installation drawing (following)
Machines A53 and A54 :

Drive end side (2 bearing machine)

Non drive end side

1 End shield

1 End shield

2 M12 stud

2 M12 stud

3 End cover

3 End cover

4 - Shaft

4 Shaft

5 Ball bearing 6232 MC3

5 Ball bearing 6328 MC3

6 Spring

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ALTERNATORS
2.3.9 Anti friction bearing installation drawing (following)
Machine type A56 ; Power plant (6 poles and more)

1 - End shield
2 - Outside bearing cover
3 - (4) Stud bolt M12/150

4 - Fixed deflector
5 - Rotating deflector
6 - Nut

7 (4) screws chc M6/16

8 - Sensors
9 - Inside bearing cover

10 - Roller bearing NUP 244

11 - Roller bearing NU 232
12 - snap ring

Machine type A56 ; Power plant (4 poles only)

1 - End shield
2 - Outside bearing cover
3 (4) Stud bolt M16-150
4 - Fixed deflector

5 - Rotating deflector
6 - Nut
7 - Screw chc M6-16
8 - Sensors

9 - Roller bearing NUP 236

10 - Inside bearing cover
11 - Roller bearing NU 232
12 - 4 Stud bolt M12-126-36

13 snap ring

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ALTERNATORS
2.4 SLEEVE BEARINGS
Note : For vertical machines refer to the attached specific
bearing notice.
Refer to the attached cut view in "chapter 10" for an easier
understanding
2.4.0 Description of horizontal Sleeve bearings
a) Physical description
Rotation of the machine rotor is guided by Sleeve bearings.
The bearing housing is constructed in two ribbed parts
providing considerable heat extraction potential.
The sleeve bearing comprises two half-shells with an
external spherical shape. This allows self-alignment. The
guiding surfaces of the sleeve bearing are covered with tinbased anti-friction metal.
The spherical seat of the housing of the electrically
insulated bearings is covered with an insulating coating.
The positioning pin of the sleeve bearing in the housing is
also insulated with an insulating bush.

c) Operating description of Oil circulation bearing

Proceed as for the self-lubricated bearings.
For special duty of high speed machine or high loaded
bearing it might be necessary to have an oil circulation
system (external device which ensure the cooling and the
circulation of the oil)
The oil warmed by the bearing losses is externally cooled
and is returned directly to the shell. To obtain efficient
cooling the oil flow must be correct (refer to section 1).
2.4.1 Electrical insulation of Sleeve bearings
a) Illustration diagram of the insulating film
Following the used technology shaft circulating current may
occurs. When necessary, ACEO insulates the Non Drive
End bearing to avoid shaft-circulating current.
An insulating film is applied to the bearing housing
spherical seat.

The lubrication ring, mounted free on the shaft, is made of

brass. In order to simplify dismantling, the ring is cut in two
parts, assembled using screws.
A guide for the lubrication ring (synthetic materials) is
attached to the upper bearing half-shell (for marine
applications only).
The floating labyrinth seals are cut in two parts, held
together by an expandable ring. These seals are inserted in
a support. A seal-positioning pin rests in the support to
block it during rotation.
The upper part of the housing is closed by means of a
glass plug allowing observation of the rotation of the
lubrication ring. A threaded metal plug allows the bearing to
be filled with oil.

1 Electrical insulation
CAUTION:
WHEN INSULATED BEARING IS USED THE
ACCESSORIES IN CONTACT WITH THE SHELL MUST
BE ELECTRICALLY INSULATED (TEMPERATURE
SENSOR )

The lower housing may be equipped with an oil-level sight

indicator, a thermometer and a temperature sensor.
b) Operating description of Self-lubricating bearing
Upon stopping, the shaft rests on the lower bearing; there
is metal-to-metal contact.
During the start-up phase, the shaft rubs against the antifriction metal of the bearing. Oil lubrication is used.
After having reached its transition speed, the shaft creates
its oil film. At this point there is no further contact between
the shaft and bearing.
CAUTION:
PROLONGED OPERATION AT EXTREMELY SLOW
ROTATION SPEEDS (SEVERAL rpm) WITHOUT
LUBRICATION COULD SERIOUSLY DAMAGE THE
SERVICE LIFE OF THE BEARING.

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b) Insulation check
Single bearing machine:
Maintain the rotor at the drive end side to insulate it from
the earth (disconnect the coupling if not done). Measure the
insulating resistance between the shaft and the ground.
The insulation should be better than 0.1 M. measured
under 500 V DC
1
4

c) Long term storage

When a sleeve bearing machine has to be stopped for
more than one year:
Drain the bearing. Place a "Silicagel" gag inside the bearing
oil sump (it is necessary to open the bearing housing to
proceed)
Place an adhesive strip along the parting lines of the
housing.
Pour the TECTYL protecting agent through the oil filling
hole of the bearing (around 50 cc). Turn the shaft several
times in order to spread the product evenly throughout the
bearing.

3
5

1 - Bearing shell
2- Insulating film
3 - Bearing housing
4 - Rotor
5 - Insulating wedging
Double bearing machine:
Maintain the rotor at the drive end side to insulate it from
the earth (disconnects the coupling; Dismount the drive end
bearing if not done). Measure the insulating resistance
between the shaft and the ground. The insulation should be
better than 0.1 M. measured under 500 V DC

CAUTION:
A VISIT OF THE BEARING (research of corrosion
marks) MUST BE DONE AT LEAST ONCE PER YEAR
CAUTION:
BEFORE START UP IT WILL BE NECESSARY TO
REMOVE THE "SILICAGEL" BAG AND TAPES
2.4.3 Oil circulation installation
a) General
This chapter applies for bearings, which need an oil
circulation system
1

7
3

Installed shell accessories (e.g: RTD) must fit 0.1 M.

measured under 500 V DC

2.4.2 Storage of Sleeve bearings machine

a) General points
CAUTION:
WE RECOMMEND THE USE OF TECTYL PRODUCTS
FROM VALVOLINE GmbH SUCH AS TYPE "511 M"
NOTE :
It is possible to start the machine up without removing the
"511.M" protection.
b) Short term storage
When a sleeve bearing machine has to be stopped for
more than one month and less than one year:

2
4

1 Oil inlet
2 Oil sight level indicator
3 Exhaust elbow
4 Immediate slope
5 Following ducts
6 Return oil sump
7 - Breather
Correct oil flow is obtained by regulating the pressure at the
bearing inlet. (item 1)

Do not drain the bearing

Pour the TECTYL protecting agent through the oil filling
hole of the bearing (around 50 cc). Turn the shaft several
times in order to spread the product evenly throughout the
bearing.

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NOTE:
Never leave the Sleeve bearing on the rinsing circuit, as
insoluble particles could enter the bearing and damage it.
The oil circulating bearings are equipped with an oil inlet
pressure regulating system (item 1)
The delivered oil pressure has to be reduced by the bearing
system before entering the bearing (to adjust about 0.1 bar
up to about 0.5 bar to get the correct oil flow, refer to
chapter 2.4.4 for start up).
A filtering unit must be installed on the supply system. The
filtering power must be at least 25 (0.025 mm).

15
60
mini

"H" > 200 mm

200 mm
mini
mini : 300mm

b) Supply line
To avoid excessive difficulties of cleaning, and to allow an
easy ducting, it is necessary to use pipes requested for
hydraulic duty
After installation of the oil lines, rinse the entire oil circuit in
order to avoid dirt or impurities entering inside the bearing
and its connections. Rinse with washing oil. It is important
to remove the instrumentation (for example, pressure
gauge, flow-meter ...) during the rinsing operation to avoid
any pollution.

Min Average slope: 150 mm / m

Install a breather as close as possible of the bearing output

The breather should be to a minimum of 200 mm above the
highest point of the bearing.
The breather line should be linked to the top side of the
main oil line
It is imperative to quickly go down after the bearing output:
Install an elbow (minimum 60) immediately after the
bearing exhaust.(item 3)
Pipe with a Minimum slope of 15 (so: a difference of 25 cm
for 100cm long) minimum 300 mm high

c) gravity oil return

The difference of level between return oil sump and bearing

exhaust must be strictly higher than "H"=200 mm

CAUTION:
REMEMBER THAT THE OIL EXHAUSTED FROM THE
BEARING GOES BACK TO THE TANK ONLY BY
GRAVITY EFFECT

The average slope of the return line must be strictly higher

than 15 cm per meter of ground line. The average slope is
based on the difference of level between bearing exhaust
and return sump oil level.

CAUTION:
NOT TO FOLLOW THESE RULES MAY CAUSE HEAVY
LEAKS BY BEARING SUMP OVERFLOW.
CAUTION:
ADVISES AND REQUEST DONE IN THIS CHAPTER DO
NOT ALLOW THE INSTALLATOR TO COMPLETE BY
ITS OWN CALCULATIONS NEEDED FOR A CORRECT
OPERATION OF ITS SYSTEM.

The oil return line must no be exposed to counter current

air flow (air which should went from the oil return sump and
go toward the bearing).
Eg: a return line which should exhaust above the oil level
inside an engine oil sump should receive a crankcase back
pressure which should have a real negative effect.
NOTE : The requested oil flow is indicated in section 1
Oil return line size :
Flange

Thread

inter
(mm)

Some bearing may have two exhaust. In this case the both
exhaust lies must be connected
Because of the requested engineering rules the return
ducts frequently have big size. Their manufacturing is
frequently done by welding. It will be necessary to clean the
welds and to rinse the oil lines before use.

Oil flow ; max

(l/min)
ISO VG 32
ISO VG46

ISO VG 68
ISO VG100

DIN DN32

G 1 "

33

7,5

5,5

DIN DN40

G 1 "

40

11

DIN DN50

G 2"

50

17

16

DIN DN65

G 2 "

66

30

25

DIN DN80

G 3"

80

45

40

20

LEROY SOMER

2327 en 02.2006 / k

SERVICE AND OPERATING MANUAL

ALTERNATORS
Connection in "Y" shape:
It is acceptable to join the return lines of two bearings. In
this case it is necessary to maintain a constant oil speed
(Pipe section after = sum of the both pipes section)

S2
S1

S1 + S2

Retighten the split line and flange screws (12) by using the
following torque values:
Bearing Size

14

18

22

28

Torque [Nm]
(lightly oiled)

170

330

570

1150

Check the firm position of the top sight glass (5).

Check the firm position of the oil sight glass (23).
If a temperature sensor or thermometer is used check they
are correctly fixed.
Retighten all screw plugs in the connection holes (4), (22),
(24) (27) by using the necessary torque values:

2.4.4 Start-up of Sleeve bearings

Plugs threads

G 3/8

G 1/2

G 3/4

G1

a) General check before start up

To identify your bearing characteristics refer to section 1

Torque [Nm]

30

40

60

110

This verification must be carried out upon the first start-up,

during periodic inspection of the bearing, or as soon as any
part of the bearing alignment is changed (coupling ...).

Plugs threads

G2

G 2 1/2

320

500

After a long shutdown period, proceed following the used

storage procedure (refer to chapter 2.4.2)
Check that the shaft has not corroded (onto journal surface;
thrust faces and seals surfaces)
Fill the bearing oil cavities with oil.
CAUTION:
THE BEARINGS ARE DELIVERED WITHOUT OIL
Clean the external parts of the bearing. Dust and dirt
impede the radiation of the heat
Check if the temperature monitoring equipment works.
b) Self-lubricating bearings start up data
To identify your bearing characteristics refer to section 1
Fill the bearing with the recommended oil. The oil must be
new, absolutely free of any traces of dust or water.

Torque [Nm]

G 1 1/4 G 1 1/2
160

230

Check the operation of the temperature monitoring

equipment.
During the start-up period, check the temperature of the
bearings. The temperature should stay below 95C and
then drop down to the temperature normally recommended
(refer to the technical characteristics for Sleeve bearings in
Section 1.)
In case of oil oozing retighten the bearing fixing screws and
the plugs to the recommended torque.
c) Water cooled bearing (type EFW..) start up data
To identify your bearing characteristics refer to section 1
Proceed as for the self-lubricated bearings and
check the water flow of the cooler. (refer to the data
contained in section 1)

The oil level limits are as follows:

minimum oil level: bottom of the oil sight glass
maximum oil level: 2/3 the top of the oil sight glass
NOTE: It is recommended to filter the oil before filling the
bearing.
CAUTION:
NOT ENOUGH LUBRICANT LEADS TO TEMPERATURE
RISES AND THUS TO DAMAGE TO THE BEARING.
TOO MUCH LUBRICANT LEADS TO LEAKAGES.

21

LEROY SOMER

SERVICE AND OPERATING MANUAL

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ALTERNATORS
d) Oil circulation bearing with non accurate oil flow
(+0% ; -40%)
To identify your bearing characteristics refer to section 1

e) Oil circulation bearing with accurate oil flow

(+5% ; -10%)
To identify your bearing characteristics refer to section 1

This chapter typically applies for standard bearings (as for

bearing types E..Z.K ; E..Z.Q).

This chapter typically applies for bearings engineered for

heavy thrust (tilting pads as for bearing types E..Z.A).

The oil circulating bearings (without Leroy Somer

lubricating system) are delivered with:
a breather
an oil inlet flow regulating system.

CAUTION:
THE OIL FLOW MUST BE CARREFULLY ADJUSTED TO
THE REQUESTED VALUE

The "oil flow regulating system" consists of :

an adjustable pressure reducing valve "A"
a diaphragm.

The oil circulating bearings are delivered with:

a breather
an oil inlet flow regulating system.

The oil flow adjustment does not request high accuracy. Do

not feed the bearing with an oil flow higher than this one
indicated in section 1.

The "oil inlet regulating system" consists of :

an adjustable pressure reducing valve "A"
a diaphragm.

Ensure that the complete oil supply and return lines have
been rinsed as instructed in the chapter.2.4.3

Ensure that the complete oil supply and return lines have
been rinsed as instructed in the chapter.2.4.3

Ensure that the installation instructions have been followed

(refer to chapter.2.4.3 ) such as filtering unit, return line
properly inclined etc.

Ensure that the installation instructions have been followed

(refer to chapter.2.4.3) such as filtering unit, return line
properly inclined etc.

Proceed as for the self-lubricated bearings and then

start the oil supply system (pump etc.).

Proceed as for the self-lubricated bearings and then

start the oil supply system (pump etc.). The oil flow must be
strictly adjusted within the requested value using a flow
meter. Run the generator.

To adjust the oil flow :

Machine stopped, adjust the pressure reducing valve "A" to
get the bearing oil level at the middle of the glass. And then
run the generator
Machine running and oil at the operating temperature the
oil sight glass level should be within 1/3 and of the glass.
If necessary readjust the pressure reducing valve "A"

During generator operation the oil level in the bearing must

comply with the indications in Chapter 2.4.5.

Machine running and oil at the operating temperature the

oil sight glass level should be within 1/3 and 2/3 of the
glass. If the level reach the top of the oil sight glass
investigate for the oil return line design.
f) Inspection of Sleeve bearings at the end of start-up
Supervise the bearing during the trial run ( 5-10 operating
hours ).
Pay special attention to:
- oil level
- bearing temperature
- sliding noises of the shaft seals
- tightness
- occurrence of vibrations.
CAUTION :
IF THE BEARING TEMPERATURE EXCEEDS THE
CALCULATED VALUE OF 15 k STOP THE MACHINE
IMMEDIATELY. INSPECT THE BEARING AND
DETERMINE THE CAUSES.
In case of oil oozing retighten the bearing fixing screws and
plugs to the recommended torque

22

2327 en 02.2006 / k

SERVICE AND OPERATING MANUAL

LEROY SOMER

ALTERNATORS
2.4.5 Maintenance of Sleeve bearings
a) Verification of oil-level
Check the oil level at regular intervals.
The oil level limits are as follows:
minimum oil level: bottom of the oil sight glass
maximum oil level: 2/3 the top of the oil sight glass

2/3

Maximum admissible oil level

Optimum top oil level
Optimum bottom oil level

1/2 1/3

Minimum admissible oil level

b) Temperature verification
Check the bearing temperature and record it. A bearing
temperature, which suddenly varies without any obvious
reason (change of ambient temperature etc.), indicates
abnormal operation. It is then necessary to inspect the
bearing.

NOTE:
Make sure that no impurities get into the bearing.
Use a lubricant with the viscosity indicated on the bearing
type plate. Fill the lubricant through the oil filler hole (4) up
to the middle point of the oil sight glass (23).
The oil level limits are as follows:
minimum oil level: bottom of the oil sight glass
maximum oil level: 2/3 the top of the oil sight glass
NOTE:
Insufficient lubricant leads to temperature rises and thus to
damage to the bearing.
Too much lubricant leads to leakage. In the case of
bearings lubricated by a loose oil ring, too much lubricant
could break the oil ring, thus leading to damage to the
bearing.
Tighten the screw plug into the oil filler hole (4) using the
following torque values:
Bearing size

14

18

22

28

c) Oil draining

Torque [Nm]

30

40

60

60

NOTE:
Risk of pollution! Please observe the instructions for the
use of the lubricating oil. The manufacturer can provide
information on waste oil disposal

d) Pressure measurement of a Sleeve bearing housing

The external environment of the electric machine may
cause pressurizing or depressurizing of the Sleeve bearing
and lead to oil leakage.

It is recommended to drain the oil at intervals of

8000 hours of operation in dirty environment (eg :
gen set application)
16000 hours of operation in clean environment (eg :
hydro power plant)

Example: The oil return line (of a circulation bearing)

opening directly into a diesel motor lower sump and
allowing the housing back-pressure to return to the bearing.

Shut down the installation and secure it against unintended

operation.

The relative depression (or pressure) during operation must

remain less than 5 mm of water column. The relative
pressure is the pressure difference existing between the
bearing oil sump and the bearing outside (measured close
to the seals).

Take all necessary measures to collect all of the lubricating

oil.
Release the lubricating oil while it is still warm. Impurities
and residues will thus be removed.
Unscrew the oil drain plug (27). Release the lubricating oil
and collect it.
NOTE:
If the lubricating oil contains unusual residues or is visibly
changed, eliminate the causes. If necessary, carry out an
inspection.
Tighten the oil drain plug (27) using the following torque
values:

Example: A vacuum generated by a coupling located too

close the Sleeve bearing and acting as a fan.

Pe : external pressure
close to the seal

Pi

Pi : bearing oil sump

pressure
Pm : machine
expansion chamber
(gain access as
indicated by the
arrow)

Pe

(Pe - Pi) < 50Pa

Bearing size

14

18

22

28

(Pm - Pi) < 50Pa

Torque [Nm]

30

40

60

60

Note: 50Pa=5mmWC

Pm

Remove the screw plugs from the oil filler hole (4).

23

SERVICE AND OPERATING MANUAL

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2327 en 02.2006 / k

ALTERNATORS
Field pressure measure :
Using a transparent tube as water column manometer.
Connect a flexible transparent tube to the upper part of the
bearing. Connect a pressure tap corresponding to the
flexible tube used.
Install the pressure tap in place of the filling plug located on
the top of the bearing housing.
Partially fill the pipe with water.
NOTE:
Be careful not to cause water to enter the bearing
Measure the pressure (or depression) in millimeters of
water column.
NOTE:
Given the low pressures measured, to make the reading
easier it is advised to incline the water column manometer
by 5.7 (diagram below). A reading amplification of "10" is
thus obtained.

5 mm

50 mm

100 mm
99mm

x
850
775
700
625
550
500
450
400
365
315
280
240
205
175
140
115
85
60
40
20
10

680
140
460

320
220

90

50
40

150
100
68
46
32
22

85

30

80
20
75

10W
0W & 5W

42
40
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2

x - CST at 40C
y - CST at 100C

5,7
10 mm

Viscosity data (for information) :

5,7

A - ISO (VG)
B - SAE J306c Transmissions
C - SAE J300d motors

e) Oil for sleeve bearing

We do not have any special recommendation regarding any
mineral oil manufacturer.
The used oil must comply with the requested viscosity
(refer to Section 1).
For frequent cold starting (lower than -15C) without oil
sump heater please contact us. A new oil viscosity may be
advised.
Use a non-foaming mineral oil, without additives. If an oil
containing additives has to be used, make sure that the
supplier confirms the chemical compatibility of the oil and
the lead anti-friction properties.
CAUTION:
SYNTHETIC OILS MAY BE USED ONLY IF USED
LUBRICANT ARE ISSUED FROM THE FOLLOWING
LIST
Since the synthetic lubricants are not standardized, no
guarantee can be given regarding their chemical and
mechanical behavior. Some synthetic lubricant may
become acid and destroys bearing parts (white metal, oil
ring, sight indicator..) in a short time
If synthetic oil has to be used; during the first 2000 hours of
use the lubricant should be checked at short intervals.

24

SERVICE AND OPERATING MANUAL

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2327 en 02.2006 / k

ALTERNATORS
Few examples of mineral oil:
Type

viscosity viscosity
(cSt ; 40C)
ISO

Vitam GF 32
Degol CL46
Degol CL 68

VG 32
VG 46
VG 68

32
46
68

BP

VG 32
VG 46
VG 68

31,5
46
68

Energol CS 32
Energol CS 46
Energol CS 68

CHEVRON

VG 32
VG 46
VG 68

30,1
43,8
61,9

Mechanism LPS 32
Mechanism LPS 46
Mechanism LPS 68

ESSO

VG 32
VG 46
VG 68

30
43
64

TERESSO 32
TERESSO 46
TERESSO 68

MOBIL

VG 32
VG 46
VG 68

30
43
64

D.T.E. Oil Light

D.T.E. Oil Medium
D.T.E. Oil Heavy Medium

VG 32
VG 46
VG 68

32
46
68

Tellus Oil 32
Tellus Oil 46
Tellus Oil 68

ARAL

SHELL

The only synthetic lubricant allowed are those one issued

from the following list
viscosit

Type

g) Sealing Compound
To ensure a good sealing effect and preserve a correct
operation of the floating labyrinth seals of the bearings we
recommend to use the following sealing compound:
Mineral oil.
On split surfaces and on the floating labyrinth seals it is
possible to use following compounds (never dry):
"Liquid gasket gray ; Three bond 1121"
"Hylomar M ; Marton-Domsel"
"Universal-Dichtmasse 200 PU ; Reinz-Dichtungs-gmbh"
On split surfaces only do not use on floating labyrinth seals)
it is possible to use following compounds :
Terostat-9140 ; Teroson
Blue silicone RTV n6 ; Loctite
Blue RTV 6B ; Permatex
Hi-Temp RTV FAG 26B ; Permatex
Synthetic oils.
Compound with a silicone base can pollute the synthetic oil.
Use it only after checking with the oil manufacturer that it is
compatible with the oil.
Without compatibility information, use never dry silicone
free compound, on all surfaces :
"Liquid gasket gray ; Three bond 1121"
"Hylomar M ; Marton-Domsel"
"Universal-Dichtmasse 200 PU ; Reinz-Dichtungs-gmbh"

(cSt ; 40C)

KLUBER

32
44
62
81

Summit SH 32
Summit SH 46
Summit SH 68
Summit SH 100

MOBIL

31
65

SHC 624
SHC 626

SHELL

32
48
68

Madrella Oil AS 32
Madrella Oil AS 46
Madrella Oil AS 68

f) Oil sump capacity (liters)

Bearing EFxxx

14

18

22

28

Volume (l)

13

21

34

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2327 en 02.2006 / k

SERVICE AND OPERATING MANUAL

ALTERNATORS
To transport the top half of the housing
2.4.6 Dismantling

Check if the eye bolts are tight (6).

a) Tools and equipment

The following tools and equipment are necessary:
- Allan key set
- Wrenching key set
- Open-jaw spanner set
- Feeler gauges (up 0.05mm)
- Caliper gauge
- Emery paper, Sleeve scraper
- Lifting equipment
- Permanent sealing compound (refer to chapter 2.4.5)
- Clean cloth
- Oil with the viscosity indicated (see bearing type plate)
- Detergents

Connect the lifting equipment to the eye bolts (6).

- Liquid screw locking compound (e.g. LOCTITE 242)

- Liquid sealing compound and Teflon tape.

Bearing size

14

Tap hole

M 8 M 12 M 12 M 16

DANGER
BEFORE TRANSPORTING OR LIFTING CHECK IF THE
EYE BOLTS ARE TIGHT! INSECURE EYE BOLTS
COULD RESULT IN THE BEARING BECOMING LOOSE.
BEFORE MOVING THE BEARING BY THE EYE BOLTS
MAKE SURE THAT THE SPLIT LINE SCREWS ARE
TIGHTENED, OTHERWISE THE BOTTOM HALF OF THE
BEARING COULD BECOME DETACHED.
MAKE SURE THAT THE EYE BOLTS ARE NOT EX
POSED TO BENDING STRESS, OTHERWISE THE
BOLTS COULD BREAK.
Follow exactly the instructions for the use of the lifting
equipment.
NOTE:
Make sure that the work place is clean. Contamination and
damage to the bearing, especially of the running surfaces,
have a negative influence on the operating quality and
could lead to premature damage.

To transport the bottom half of the housing

Screw 2 eye bolts (6) with suitable threads tight into the tap
holes (17) marked with a cross.
Bearing size
Tap hole

14

18

22

28

M 16 M 20 M 24 M 30

Connect the lifting equipment to the eye bolts (6).

To transport the Bearing shells
Screw 2 eye bolts or screw hooks with suitable threads tight
into the tap holes (9):
18

22

28

Connect the lifting equipment to the screw hooks.

c) Dismantling of the shaft seal type 10 (outboard side)
Loosen all screws (55) and turn them off.
Remove simultaneously in axial direction both top half (48)
and bottom half (51) of the seal carrier from the housing.
Shift the top half of the seal (53) a little (about 20 mm ). Tilt
it over carefully until the hook spring (49) unbends.
DANGER:
DURING DISMANTLING OF THE FLOATING
LABYRINTH SEAL HOLD TIGHT THE HOOK SPRING
(38). THIS IS UNDER TENSION AND COULD SPRING
BACK AND LEAD TO INJURY.
Open the hook spring (49) and remove the bottom half of
the seal (52) from the shaft.
d) Dismantling of the shaft seal type 20 (outboard side)
Untight all seals fixing screw (49) and remove them.

Shut down the installation and ensure that any unintended

operation is prevented.

Simultaneously remove in axial direction both top and

bottom (48) ,(52) halves of the rigid labyrinth seal.

Interrupt the cooling water supply (EFW.. bearing only).

- Remove the split line screws (50).

Remove all thermo sensors from the connection holes.

- Separate the top half of the rigid labyrinth seal (59) from
the bottom half (63).

Take all necessary measures to collect the lubricating oil.

Unscrew the oil drain plug (27) and collect the lubricating oil
(refer to chapter 2.4.5.c)

e) Dismantling of the top half of the housing

Remove the flange screws (8).

b) Lifting equipment
The following steps are to be observed before using the
lifting equipment:

Remove the split line screws (12).

To transport the complete bearing unit

Check if the split line screws are tight (12):
Check if the eye bolts are tight (6).
Connect the lifting equipment to the eye bolts (6).

Lift the top part of the housing (1) until the top part of the
housing can be moved in axial line over the bearing shell,
without touching it.

26

LEROY SOMER

SERVICE AND OPERATING MANUAL

2327 en 02.2006 / k

ALTERNATORS
f) Removal of the top half of the shell
Unscrew the split line screws (19) and lift the top half of the
shell (11).

h) Dismantling the machine side shaft seal

Shift the top half of the seal (53) a little (about 20 mm). Tilt
it over carefully until the hook spring (49) unbends.

CAUTION:
DO NOT DAMAGE THE THRUST AND RADIAL
RUNNING SURFACES.

DANGER:
DURING DISMANTLING OF THE FLOATING
LABYRINTH SEAL HOLD TIGHT THE HOOK SPRING
(38). THIS IS UNDER TENSION AND COULD SPRING
BACK AND LEAD TO INJURY.

g) Dismantling of the loose oil ring

Open both split lines of the loose oil ring (44) by
untightening and removing the screws (47). Separate both
halves of the loose oil ring (44) carefully without using any
tools or other devices.

Open the hook spring (49) and turn the bottom half of the
seal (52) in the opposite direction to the anti-rotation pin out
of the integrated seal groove of the bottom half of the
housing.
i) Removal of the bottom half of the shell
CAUTION:
MAKE SURE THAT ALL BEARINGS MOUNTED ON A
SHAFT LINE ARE OPENED. LOOSEN THE SPLIT LINE
SCREWS OF THE HOUSINGS.
CAUTION:
THE LIFTING EQUIPMENT SHOULD NOT COME IN
TOUCH WITH THE SEAL AND RUNNING SURFACES
OF THE SHAFT.
Lift the shaft up to the point where shaft and bottom half of
the shell (13) do not touch each other any more. Protect the
shaft against unintended movement.
Turn the bottom half of the shell (13) out of the bottom half
of the housing (21) and remove it from the shaft.
j) Dismantling of the machine seal
Usually it is not necessary to dismantle the machine seal
(10) if maintenance works are carried out.

Illustration 1 : Opening of the loose oil ring

To check the geometry of the loose oil ring put it together
as follows:
Press the positioning pin (45) into the holes (46).
Adjust both halves of the loose oil ring till the split lines
match each other.
Tighten the screws (47).

If due to certain reasons the split machine seal must be

dismantled please observe that this operation can be
carried out only from the inner part of the machine. Loosen
the split line screws of the machine seal and remove the
flange screws (7).
Non-split machine seals can be dismantled only after
dismantling the machine shield or the shaft completely.
In the case the machine seal is equipped with a hamp
packing, some visible changes can be noticed, such as :
tallow excess, black color of the seal due to temperature
development. Even in such cases it is not necessary to
renew the hamp packing. Color changes will appear with a
new hamp packing too, until the seal clearance adjusts
during operation.

27

LEROY SOMER

SERVICE AND OPERATING MANUAL

2327 en 02.2006 / k

ALTERNATORS
2.4.7 Cleaning and checking
a) Cleaning
CAUTION:
USE ONLY NON-AGGRESSIVE DETERGENTS SUCH
AS FOR INSTANCE
VALVOLINE 150
ALKALINE CLEANING COMPOUNDS (PH-VALUE 6 TO
9, SHORT REACTION TIME).

b) Wear checking
Carry out a visual check of the wear condition of all bearing
parts. The following graph provides information on the parts
that must be replaced in case of wear. The right evaluation
of the wear condition, especially of the running surfaces of
the bearing shell, implies a lot of experience. If in doubt,
replace the worn part with new ones.
Part

Wear condition

Maintenance proceedings

Shell

Scoring

Bearing temperature before

inspection:
not increased no new
shells
increased
new shells

DANGER:
PLEASE OBSERVE THE INSTRUCTIONS FOR THE USE
OF THE DETERGENTS.
CAUTION:
NEVER USE CLEANING WOOL OR CLOTH. RESIDUES
OF SUCH MATERIALS LEFT IN THE BEARING COULD
LEAD TO EXCESSIVE TEMPERATURES.
Clean the following parts thoroughly :
top half of the housing (1)
bottom half of the housing (21)
top half of the shell (11)
bottom half of the shell (13)
sealing surfaces of the top half (48) and bottom half (51)
of the seal carrier or of the rigid labyrinth seal
loose oil ring (44).
Water cooler cleaning (bearing type EFW.. only)
Check the condition of the oil cooler (26).
In case the oil cooler (26) is encrusted with oil sludge:

White metal lining New shell

damaged
Shaft
seal

Bow wave ridges

New shells

Baffles broken or
damaged

New shaft seal

Loose Geometrical form New loose oil ring

oil ring (roundness,
flatness ) visibly
changed

c) Insulation checking (only for insulated bearing)

Check the insulating layer of the spherical seating (14) of
the top half (1) and bottom half (21) of the housing. In case
of damage contact Leroy Somer; dpartement ACEO
factory.

Dismantle the oil cooler. Remove the encrustation by using

for instance a wire brush.
Install the oil cooler (26) into the bearing.

28

LEROY SOMER

SERVICE AND OPERATING MANUAL

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ALTERNATORS
2.4.8 Assembly of the Bearing
CAUTION:
REMOVE ALL IMPURITIES OR OTHER OBJECTS SUCH
AS SCREWS, NUTS, ETC. FROM INSIDE THE
BEARING. IF LEFT INSIDE THEY COULD LEAD TO
DAMAGE OF THE BEARING. COVER UP THE OPENED
BEARING DURING BREAKS.
CAUTION:
CARRY OUT ALL ASSEMBLY OPERATIONS WITHOUT
MAKING USE OF FORCE.

CAUTION:
THE FLOATING LABYRINTH SEAL SHOULD TURN
EASILY ON THE SHAFT. A JAMMED SEAL COULD
LEAD TO OVERHEATING DURING OPERATION AND
EVEN TO SHAFT WEAR.
If the floating labyrinth seal jams, dismantle it from the
shaft. Remove the worn parts of the seal carefully, by using
emery paper or a Sleeve scraper.
Dismantle the floating labyrinth seal.
Apply sealing compound on the guide surfaces of the
integrated seal groove in the bottom half of the housing.

CAUTION:
USE A LIQUID SCREW LOCKING COMPOUND (E.G.
LOCTITE 242) FOR ALL HOUSING, SPLIT LINE AND
FLANGE SCREWS.
a) Fitting in the bottom half of the shell
Apply some lubricant on the spherical seating (14) in the
bottom half of the housing (21) and on the running surfaces
of the shaft. Use the same type of lubricant as indicated for
bearing operation ( see type plate ).
Place the bottom half of the shell (13) on the running
surface of the shaft. Turn the bottom half of the shell (13)
into the bottom half of the housing (21) with the split line
surfaces of both halves in true alignment.

Illustration 2: Coating of sealing compound on the

integrated seal groove
Apply a uniform layer of sealing compound on the seal
surfaces and on the split line surfaces of both halves of the
seal (52), (53).

In case the bottom half of the shell does not turn in easily,
check the position of the shaft and the alignment of the
bearing housing
CAUTION:
(ONLY FOR BEARINGS EF..K)
THESE OPERATIONS SHOULD BE CARRIED OUT
MOST CAREFULLY. THE THRUST PARTS OF THE
BOTTOM SHELL SHOULD NOT BE DAMAGED.
Lower down the shaft till it sits on the bottom half of the
shell (13).
b) Assembly of the shaft seal machine-side
The machine-side shaft seal is standard-wise a floating
labyrinth seal. The integrated seal groove is in the top and
bottom halves of the housing.
DANGER:
DURING ASSEMBLY HOLD THE HOOK SPRING ENDS
(38) SECURELY TO AVOID THEM SUDDENLY
RELEASING AND CAUSING POSSIBLE INJURY!
Check the movement of the floating labyrinth seal on the
shaft in the seal area outside the housing:

Illustration 3 : Coating of sealing compound on the floating

labyrinth seal
Place the bottom half of the seal (52) with the labyrinths
onto the shaft.
The oil return holes at the bearing side must be opened.
Turn the seal in the opposite direction to the anti-rotation
pin into the groove of the housing until the split lines of the
bottom half of the housing and the bottom half of the seal
match each other.
Remove the rest of the sealing compound.

Put the hook spring (49) around the shaft and hook both
ends into each other.

Push the spring hook into the integrated seal groove

between the bottom half of the housing and the seal until
both ends jut out from the split line.

Put both halves of the seal (52), (53) in their place on the
shaft.

Place the top half of the seal with the cam facing the inside
of the bearing on the bottom half of the seal.

Put the hook spring (49) into the spring groove (50).

Stretch the hook spring until both ends can be hooked.

Turn the floating labyrinth seal on the shaft.

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ALTERNATORS
c) Installation of the loose oil ring
Open both split lines of the loose oil ring (44) by
untightening and removing the screws (47). Separate both
halves of the loose oil ring (44) carefully without using any
tools or other devices.

d) Fitting in the top half of the shell

Apply some lubricant on the running surfaces of the shaft.
Use the same type of lubricant as indicated for bearing
operation (see type plate).
Check if the engraved numbers (15) on the bottom and top
halves of the shell correspond.
Place the top half of the shell (11) on the shaft; both
engraved numbers (15) should be on the same side.
CAUTION :
AN INCORRECTLY PLACED SHELL COULD JAM THE
SHAFT THUS LEADING TO THE DAMAGE OF BOTH
SHAFT AND BEARING.
CAUTION : (FOR BEARINGS TYPE EF..K ONLY)
PLACE THE TOP HALF OF THE SHELL CAREFULLY
ON THE SHAFT. THE THRUST PARTS OF THE TOP
HALF OF THE SHELL SHOULD NOT BE DAMAGED.
Tighten up the split line screws (19) by using the following
torque values:
Bearing size

14

18

22

28

Torque [Nm]

20

69

69

170

Check the split line of the bearing shell by using a feeler

gauge. The split line gap should be less than 0.05 mm. If
the split line is greater than this, dismantle both top and
bottom (11), (13) halves of the shell.
Check the mobility of the loose oil ring (44).
Illustration 4 : Opening of the loose oil ring
Place both halves of the loose oil ring into the shell groove
(13) encircling the shaft. Press the positioning pin (45) of
each split line into the corresponding hole (46).
Adjust both halves of the loose oil ring until the split lines
match each other.
21
34
33

33

13

Marine bearing only:

A guide bush in the top half of the shell secures the
function of the loose oil ring.
Check the mobility of the loose oil ring (44) in the guide
bush.
e) Closing of the bearing
Check the true alignment of the shell (11), (13) and bottom
half (21) of the housing.
The positioning pin (3) in the top half of the housing fits in
the corresponding positioning pin hole (2). The bearing
shell is thus placed into its right position.
Check if the engraved numbers (20) on the top and bottom
halves of the housing correspond.
Clean the split line surfaces of the top and bottom halves
(1), (21) of the housing.
Apply sealing compound over the whole surface of the split
line of the bottom half (21) of the housing.

Illustration 5 : Installation of the loose oil ring

Tighten the screws (47) by using the following torque
values:
Bearing size

14

18

22

28

Torque [Nm]

1,4

2,7

2,7

2,7

Place the top half of the housing carefully into the machine
shield, without touching the seals or the bearing shell.

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ALTERNATORS
Lower the top half of the housing (1) vertically on the
bottom half of the housing (21). Lower the top half of the
housing (1) until the split line of the housing is not visible
any more.
Gently hit the bottom half of the housing (21) with a nylon
hammer, thus ensuring the alignment of the spherical
seating.

Press the bottom half of the seal (52) against the shaft.
Place the top half of the seal (53) on the shaft and align
both halves of the seal to each other.
Place the hook spring (49) into the spring groove (50) and
stretch until both ends can be hooked.
43

38

41

42

21

Insert the split line screws (12). Tighten them hand-tight.

Insert the flange screws (8). Tighten them using the
following torque values:
Bearing size

14

18

22

28

Torque [Nm]

170

330

570 1150

Tighten the split line screws (12) of the housing crosswise

using the same torque values
f) Assembly of the type 10 Outboard Side Seals
DANGER:
DURING ASSEMBLY HOLD THE HOOK SPRING ENDS
(49) SECURELY TO AVOID THEM SUDDENLY
RELEASING AND CAUSING POSSIBLE INJURY!
Check the movement of the floating labyrinth seal on the
shaft in the seal area outside the housing.
Place the hook spring (49) around the shaft and hook both
ends into each other.
Locate both halves of the seal (52), (53) in their place on
the shaft.
Locate the hook spring (49) in the spring groove (50).
Turn the floating labyrinth seal on the shaft.
CAUTION:
THE FLOATING LABYRINTH SEAL SHOULD TURN
EASILY ON THE SHAFT. A JAMMED SEAL COULD
LEAD TO OVERHEATING DURING OPERATION AND
EVEN TO SHAFT WEAR.
If the floating labyrinth seal jams, dismantle it from the
shaft. Remove the worn parts of the seal carefully, by using
emery paper or a Sleeve scraper.
Dismantle the floating labyrinth seal.
Apply a uniform layer of sealing compound on the seal
surfaces and on the split line surfaces of both halves of the
seal (52), (53).

Illustration 7 : Assembly of the floating labyrinth seal

Align the split line of the floating labyrinth seal and the split
line of the seal carrier.
Check that both engraved numbers (56)and(58) on top and
bottom halves of the seal carrier (48), (51) correspond.
Clean the following:
the seal surfaces of the top (48) and bottom (51) half of the
seal parts: carrier (the groove of the floating labyrinth seal,
the flange surfaces)
the split line surfaces of the top (48) and bottom (51) half of
the carrier
the flange surfaces of the housing.
Apply a uniform layer of sealing compound on:
the lateral surfaces of the groove at the top (48) and bottom
(51) half of the seal carrier
the flange surfaces of the top (48) and bottom (51) half of
the seal carrier
the split line surfaces of the bottom half of the seal carrier
(51).

Illustration 8 : Application of sealing compound on the seal

carrier
Illustration 6 : Application of sealing compound on the
floating labyrinth seal

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ALTERNATORS
Place the top half of the seal carrier (48) on the top half of
the seal (53). Press the bottom half (51) of the seal carrier
against it. Push the shaft seal completely into the housing.

Place the top half (59) of the rigid labyrinth seal on the shaft
and press slightly the bottom half (63) of the rigid labyrinth
seal from below against it. Lightly push the rigid labyrinth
seal completely into the housing.
Tighten the split line screws (61).
Place in parallel alignment the split line of the rigid labyrinth
seal and the split line of the housing.
CAUTION:
PRESS THE RIGID LABYRINTH SEAL FROM BELOW
AGAINST THE SHAFT
Adjust the rigid labyrinth seal in such a way that the
clearance "f" between the shaft and the rigid labyrinth seal
at both split lines has the same figure.

Illustration 9 : Assembly of the seal carrier

Align the split lines of the seal carrier and the housing.
Tighten up the screws (55) by using the torque values:
Bearing size

14

18

22

28

Torque [Nm]

20

20

20

g) Assembly of the type 20 Outboard Side Seals

Check if the engraved numbers on the bottom half (63) and
top half (59) of the rigid labyrinth seal correspond.
Clean the flange surfaces of
the top half and bottom half (63) of the rigid labyrinth seal
the split line surfaces of the top half and bottom half (63) of
the rigid labyrinth seal
the flange surfaces of the housing.
Apply a uniform layer of sealing compound on the following
parts:
the flange surfaces of the top (59) and bottom half (63) of
the rigid labyrinth seal
the split lines of the bottom half (63) of the rigid labyrinth
seal.

Illustration 11: Alignment of the rigid labyrinth seal

Tighten the screws (60) by using the following torque
values:
Bearing size

14

18

22

28

Torque [N.m]

20

20

20

h) Assembly of the RD-thrust pads ; bearing type E...A

Clean both top and bottom halves of the shroud ring and all
RD-thrust pads..
Check if the parts show any visible damage.

Carry out the assembly of both thrust parts of the top

(6) and bottom (27) half of the shell according to the
following instructions:
An RD-thrust pad on both sides of the top half of the shell
has a bore for the insertion of a thermo sensor ( thrust part
temperature measurement).
To mount the RD-thrust pad into the correct position
proceed as follows:
- Find the position of the location hole (38) on the top half
of the shroud ring (39).Insert the RD-thrust pad (42) with
the anti-rotation pin (43) into the corresponding thrust pad
location hole (37).
Insert all other RD-thrust pads (42) into the corresponding
thrust pad holes (37)
of the top and bottom half of the shell (6),(27).

Illustration 10: Application of sealing compound on the rigid

labyrinth seal

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ALTERNATORS
2.4.9 Oil-leakage trouble-shooting
Oil leakage can occur in the Sleeve bearings if certain
measures are not taken.
a) Self-lubricating bearing
- Is the oil level correct? (see chapter 2.4.5.a )
- Is the Sleeve bearing in decompression? (see chapter
2.4.5.d ). If the depression level is abnormal, add a
protective screen.

Illustration 1:

Assembly of the RD-thrust pads

Place the top half of the shroud ring (39) into the top half of
the shell (6) by inserting the anti-rotation pin (43) into the
location hole (38). Match the split line of the top half of the
shell (6) with the split line of the top half of the shroud ring
(39) in true alignment.

- Is the leakage occurring around the parting line? Clean

the parting lines carefully with a solvent. Apply a sealing
compound (refer to chapter 2.4.5) upon reassembly (see
chapter 2.4.6)
b) Oil circulation bearing
- All information and instructions concerning the "selflubricating bearings" apply.
- Is the bearing oil flow correct (for data refer to section 1)?
To adjust the oil flow refer to chapter 2.4.4
-Is the Sleeve bearing under pressure?
To measure refer to chapter 2.4.5 . This pressure most
certainly comes from the oil-return circuit. Check the oilreturn circuit (refer to chapter 2.4.3 ). The back-pressure
can often be eliminated by inserting a siphon-effect on the
oil-return line (then make sure that the circuit modification
does not disturb the oil-return flow).
2.4.10 Sleeve bearing protection devices
a) Sight-level glass
A sight-level gauge is placed on each bearing housing (on
the left or the right). The level control method is described
in chapter 2.4.5 a

Illustration 2:

Assembly of the shroud ring

Tighten the screws (40) by using the following torque

values:
Bearing size

14

18

22

28

Tap hole

M5

M6

M8

M10

Torque [N.m]

2,7

20

40

b) Oil thermometer (optional)

The thermometer gives the oil sump temperature.
The recorded oil sump temperature must stay below 85C
in normal condition.

Place the bottom half of the shroud ring (41) into the
bottom half of the shell (27). Match the
corresponding split lines in true alignment. Tighten
the screws (40) with the same torque value as valid
for the top half of the shell (6).
Check the mobility of all RD-thrust pads (42).
If the RD-thrust pads jam, realign the top (39) and bottom
half (41) of the shroud ring.
CAUTION
INSUFFICIENT MOBILITY OF THE RD-THRUST PADS
WILL CAUSE DAMAGE OF THE BEARING.

Both top and bottom halves of the shells are

prepared for assembly.

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ALTERNATORS
c) Thermostat or sensor (optional)
The recorded oil sump temperature must stay below 85C
in normal condition.
The shell temperature must stay below 90C in normal
condition.

2.7 COOLER
2.7.0 Description of the cooler

Shell metal ; Alarm points and shutdown:

alarm
95C (203F)
shutdown
100C (212F)

a) General points
The purpose of the cooler is to remove machine heat
losses (mechanical, ohmic etc). The exchanger is located
on the top of the machine.

Oil sump ; Alarm points and shutdown:

alarm
85C (185F)
shutdown
90C (194F)

Normal operation:
The internal air goes through the exchanger, transferring
the heat and then goes back to the machine.

To improve the bearing protection the temperature set

points can reduced following the effective site condition
Alarm temperature (*) = Highest recorded temp + 5K
Trip temperature (*) = Alarm temperature + 5 K
(*)Highest recorded temp: Temperature measured at the
site in the worst temperature
Eg: A bearing reach 80C in the worst site condition
Adjust the alarm set point to 85C instead of 95C as
previously recommended.
Adjust the trip set point to 90C instead of 100C as
previously recommended.
d) Pre lub pump (optional)
A pump takes up the oil from the bearing oil sump and
pours it over the bearing shell.
This pump ensures bearing lubrication, increasing the
greasing effect during operation at very low speed and start
up period

CAUTION:
THE COOLER MUST BE FULLY OPERATIONAL AS
SOON AS THE MACHINE IS ROTATING (EVEN IF THE
MACHINE IS RUN AT NO LOAD !)
b) Description of Air/Air coolers
The internal air flow is moved by a fan fixed on the machine
shaft. The internal cooling air circulates through the
machine and through the air-cooler in a closed circuit.
The External air circulation can be created through natural
ventilation (machine class IC 5 A1 A1) or through separate
ventilation(machine class IC 5 A1 A7).
1
air
air

Check the electrical connection of the pump motor to be

sure of the rotation direction (the rotation direction is
indicated on the pump).
The pump has to be run few seconds before the
synchronous machine starting (pre lub effect) and stopped
as soon as the main shaft line pass over200 rpm
For application having a long stop period (time over 5
minutes; eg: Steam Turbine, hydro turbine) the pump has
to be run as soon as the speed pass below 200 rpm
The pump has to be run continuously during barring period
(eg: engine maintenance)

3 air
2

1 - Air to Air cooler

2 - Ambient air
3 - Internal air
The air-cooler comprises a main housing containing the
tubes and an end housing which act as an air guide

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ALTERNATORS
c) Description Air/Water double tube exchanger
The internal air flow is moved by a fan fixed on the machine
shaft. The internal cooling air circulates through the
machine and through the air-cooler in a closed circuit. The
internal air circulation can be created through natural
ventilation (machine class IC 8 A1 W7) or through separate
ventilation (machine class IC 8 A6 W7).
Eg : machine class IC 8 A1 W7

air

air

d) Description of Air/Water single tube exchanger

The internal air flow is moved by a fan fixed on the machine
shaft. The internal cooling air circulates through the
machine and through the air-cooler in a closed circuit. The
internal air circulation can be created through natural
ventilation (machine class IC 8 A1 W7) or through separate
ventilation(machine class IC 8 A6 W7).
An exchanger comprises a fin-tube block containing
a steel frame
a fin-tube block crimped mechanically onto the tubes.
The tube bundle is roll-expanded in the end plates
The water distribution in the tubes is provided by two water
boxes. One water box is equipped with collars for fitting the
inlet and outlet water lines. Neoprene seals provide
watertightness between the water boxes and the end
plates.

air

1 Air to Water cooler

The double-tube technique keeps the cooling circuit from
being affected by possible water leakage. The double tube
provides a high safety level. In case of leakage, the water
goes from the inside of the internal tube to the coaxial
space between the two tubes. The water is drained axially
to a leakage chamber where it may activate a sensor.
An exchanger comprises a fin-tube block containing :
a steel frame.
a fin-tube block crimped mechanically to the tubes.
The tube bundle is roll-expanded in the end plates (parts 3
and 4)
The water distribution in the tubes is provided by two
removable water boxes (part 5). A water box is equipped
with collars for fitting the inlet and outlet lines. Neoprene
seals ensure watertightness between the water boxes and
the end plates.

1 - Tube with fins

2 - End plate
3 - Water bar
A - Air

B - Water

2.7.1 Start-up of the cooler

a) General points
Make sure that the safety devices are operating.
Connect the supply and return lines.

Fill with water, whilst carefully draining the circuit.

CAUTION: (machine with motorized fan only)

WE RECOMMEND THAT THE FREE OPERATION OF
THE FAN BE CHECKED (NO FRICTION, NO
BLOCKING).

5
6 4

1 - Single internal tube

2 - External tube with internal grooving and with External
fins
3 - Internal plate
4 - External plate
5 - Outside wall of the pressure tank
6 - Flow of water or liquid leaks
A - Air

B - Leakage

C - Water

CAUTION:
BEFORE START-UP, CHECK THE CLEANLINESS OF
THE COOLER FINS.
Start up the installation (if the other sub-assemblies allow
this).
Load the machine (KVA); adjust the water flow-rate to
obtain the rated flow-rate (refer to Section 1).
Check the watertightness of the lines and of the exchanger.
Check that the temperatures comply with the
recommended temperatures.

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ALTERNATORS
2.7.2 Maintenance of the water-cooler

2.7.3 Servicing the water-cooler

a) General points

a) Cooler removal
The cooler unit is slid into its housing. It is possible to
remove the cooler from the housing without removing the
water boxes. The cooler is fastened to the housing via a
series of screws on the housing.

A regular cooler clogging will have the result to a regular

winding temperature increasing
The cooler cleaning period is mainly function of the water
purity
In case of used of non recirculated water with risk (eg: river
water with algae passing trough the cooler) we recommend
a tubes visit after one year of operation. The following visit
should be forecasted following the observed dust level.
b) Cleaning
Stop the machine.
Cut off the power supply by isolating the inlet and outlet
lines, and drain the water.
Disconnect the leak sensor (option with double-tube
cooler), and make sure that there are no leaks.
Remove the water boxes on each side of the machine.
Rinse and brush each water box.
NOTE:
Do not use a hard wire brush as this will remove the
protective oxidation layer which has formed on the surfaces
of the water boxes. Clean each tube with a metal scraper.
Rinse in soft water.

Remove the supply and return pipes.

Provide two supports to hold the cooler when it comes out
of its housing.
Remove the cooler using slings that can be attached to the
connecting flanges.
b) Cooler re-assembly
Carry out the operations of the "Cooler Removal" chapter in
the reverse order. Be careful to push the cooler completely
into its housing before tightening the fastening screws of
the cooler to the casing.
2.7.4 Cooler protection devices
a) Leak detection (float system)
A magnet float activates a switch located in the float
guiding rod

A
x

Keep the leakage chamber dry (double-tube water-cooler

only)

Proceed to a gasket change

c) Leak detection for a double-tube exchanger

If a leak is detected, it is necessary to ascertain its origin
immediately and repair it.
Remove the two water boxes, apply a slight positive
pressure in the leakage chamber and thus between the two
tubes (only concerns double-tube coolers).
If a tube is damaged plug it at BOTH ends. Use a tapered
plug. The plug should preferably be made of salt-water
resistant aluminum bronze or of a synthetic material.

2
1 - Guide rod
2 - Magnetic float
A No potential contacts
x - Blue
y - Brown
z Black
b) Water temperature sensor (optional)
A temperature sensor may be installed into the water inlet
flow of the cooler.
Proposal of adjustment of the water inlet sensor :
Alarm temperature (*) = Water site temp max + 5 K
Trip temperature (*) = Alarm temperature + 5 K

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ALTERNATORS
2.8 AIR FILTERS

2.18 TERMINAL BOX

2.8.1. Cleaning

2.18.0 Description
Use the attached Terminal box drawing

a) Air filter cleaning period

The cleaning period depends of the site conditions and can
change
The cleaning of the filter is requested if the record of the
stator winding temperature (using the stator winding
sensors) indicates an abnormal increase in temperature.
b) Air filter, cleaning procedure
The filter element (flat or cylindrical) is immersed in a tank
of cold or warm water (temperature less than 50C). Use
water with detergent added.
Shake the filter gently to ensure that the water flows
through the filter in both directions.
When the filter is clean, rinse it with clear water.
Drain the filter properly (there must be no more formation of
droplets)

The main terminal box of the machine is located on the top

of the machine.
The neutral and phase wires are connected to the
terminals, one terminal per phase and one terminal per
neutral line. See "Terminal Box" diagram.
The openings provide access to the terminals.
The gland plates are made of non-magnetic materials in
order to avoid circulating currents.
The connection of accessories is achieved by terminal
strips. Use a 5 mm maximum screwdriver to work on the
blocking screws. See the "Machine Protection Devices"
diagram.
If products have to be added in the terminal box (CTs,
VTs, Shunt ex) refer to chapter.4.4.3

Refit the filter on the machine.

2.18.1 Electric panel

CAUTION:
DO NOT USE WATER WITH A TEMPERATURE HIGHER
THAN 50C, DO NOT USE SOLVENTS.

a) Compounding panel (if compound regulator)

The compounding panel is located in the terminal box

NOTE :
Do not clean the filter using compressed air. This
procedure would reduce filter efficiency.

The three current transformers (TI 01, TI 02, TI 03), fitted in

the terminal box on three power supply conductors, supply
the compounding panel.
Rectifier bridges (CR 01, CR 02) rectify the alternating
current coming from these three transformers.
An RC circuit (R 01, C 01) acts as a filter; CR 03 protects
the system from high voltage spikes.
R 02 is an assembly of two adjustable resistors (adjusted at
the factory). Refer to the regulator manual.
L 01 is an adjustable self-inducting coil comprising three
coils. The different positions of the jumpers are shown on a
plate attached to the self-inducting coil. L 01 is adjusted to
supply excitation with no load. Refer to the regulator
manual.
b) Booster plate ( if shunt + booster regulator)
The booster plate is located in the terminal box.
The three current transformers TI 01, TI 02, TI 03, fitted to
three power supply conductors, supply the booster plate.
Rectifier bridges (CR 01, CR 02) rectify the alternating
current from these three transformers.
An RC circuit (R 01, C 01) acts as a filter. CR 03 protects
the system from high voltage spikes.
R 02 is an assembly of two adjustable resistors (adjusted in
the factory). Refer to the regulator manual, section
"Principle of Excitation-Regulation".

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ALTERNATORS
2.18.2 Automatic voltage regulator
When the automatic voltage regulator is located in the
terminal box, it is fitted on a separate plate, insulated from
vibration by means of dampening pads. The operation of
the regulator is explained in chapter 3.

3. VOLTAGE REGULATOR AND EXTERNAL

AUXILIARIES
The regulator instruction manual may be considered as an
independent manual, included in the machine instruction
manual.

CAUTION :
THE DAMPENING PADS MUST BE CHECKED
PERIODICALLY AND REPLACED EVERY THREE
YEARS
2.18.3 Electrical contact tightening
Applicable for brass thread
Thread

M5

M6

M8

Torque
[Nm]

2.5

M10 M12 M14 M16

20

35

57

87

2.19 PROTECTION DEVICES

2.19.1 Stator protection devices
See "Stator protection" in chapter 2.1.3.
2.19.2 Bearing protection devices
See "Bearing protection" in chapter 2.3.5 or chapter 2.4.9
2.19.3 Cooler protection devices
See "Cooler safety" in chapter 2.7.4

2.20 NAMEPLATES
2.20.1. Main nameplate
The main nameplate is fitted to the stator. It gives the
manufacturer's electrical characteristics, the type of
machine and its serial number.
For machines with anti-friction bearings, the quantity of
grease, the type and frequency of lubrication are stipulated.
2.20.2. Lubrication nameplate
The machines with Sleeve bearings have a lubrication plate
attached to the bearing, giving:
Oil change frequency; Oil capacity of bearing; Oil viscosity.
The machines with anti-friction bearings have a lubrication
plate fixed on the stator, giving :
Type of bearing; Grease-change frequency; Quantity of
grease.
2.20.3. Rotation direction nameplate
An arrow on the drive end bearing indicates the rotation
direction.

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ALTERNATORS
4. INSTALLATION

4.2 INSTALLATION OF THE ELECTRIC

MACHINE

4.1 STORAGE
4.1.1 Storage warehouse
The machine must be stored in clean and dry premises
which are not subject to abrupt changes in temperature or
to high humidity.
Storage at an ambient temperature of +5 to +45 C is
recommended.
The machine must not be subject to vibrations.
4.1.2 Maritime packing
The synchronous machine is carefully packed in a wooden
crate, then hermetically sealed.
Breaking the hermetic protective film discharges ACEO of
its long-duration storage guarantee.
4.1.3 Unpacking and installation
DANGER :
THE FOUR LIFTING HOOKS MUST BE USED TO LIFT
THE MACHINE WITH SLINGS (ONE HOOK AT EACH
CORNER OF THE MACHINE)
Rotors of machines with Sleeve bearings and singlebearing machines, are blocked during transportation so as
to avoid any movement. Withdraw the retaining bars. The
retaining bar is screwed to the end of the shaft and to the
front support.

4.2.1 Fitting the coupling (double-bearing machine

only)
The coupling must be balanced separately before assembly
on the machine shaft. Refer to the balancing instructions in
chapter 2.2.5.
The shrinking of the half coupling onto the electrical
machine shaft end must be choose, by the gen-set
manufacturer, in such way as it should be removable for
maintenance (e.g.: bearing change).
4.2.2 Fitting the stator
Four plates on the frame enable the unit to be fitted to a
skid.
The fixing bolts must support the forces created by the
static and dynamic loads.
The machine may be positioned by means of 4 dowel pins.
The dowel pins make later realignment easier. (The use of
pins is optional).
The machine may be aligned through the use of 4 jackingscrews. These jacking-screws allow the machine to be
positioned according to the various axes.

The end of the shaft is protected from corrosion. Clean it

before coupling.
4.1.4 Storage measures of a site machine
Before stopping the machine for a long period (several
months), it is essential to take several precautionary
measures:
Refer to chapter 2.3.2 (anti friction machine) or chapter
2.4.2 (sleeve bearing machine)
The heating resistor must be switched on at all times.
For water-coolers, the water flow must be shut off. If the
water is not treated and if there is likelihood of freezing, the
exchanger must be drained.
For an open machine, it is recommended that the air inlet
and outlet be closed.
Before starting the machine up again, it will be necessary to
carry out a start-up inspection.

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SERVICE AND OPERATING MANUAL

ALTERNATORS
4.3 ELECTRIC MACHINE ALIGNMENT

c) Sleeve bearing shaft elevation

The calculated displacement is given in " section 1"

4.3.1 Alignment general points

Exact Sleeve bearing elevation due to the oil film :

The machine goes from point "1" to point "2".

a) General points
The alignment consist to obtain the driving shaft and the
driven shaft coaxial when operating at the nominal
conditions (machine rotating ; at its operating temperature)

-X
Y

The machine must be aligned according to the ACEO

standard and adhere to the manufacturer's alignment
standard for the drive machine.
When heating the machine has its shaft line which grow up.
Between stop and rotation the shaft axis location inside its
bearing is different. The total axis height elevation is
composed of the thermal elevation and of the bearing
elevation.
CAUTION:
THE ALIGNMENT MUST BE DONE TAKING IN
CONSIDERATION THE SHAFT MOVEMENT
CORRECTION
The correct locating of the parts must be obtained by
inserting shims under the machine pads..
The double-bearing machines are mounted with bearings
(ball or roller) or Sleeve bearings. The axial clearance of
the bearings (if the machine has Sleeve bearings) must be
distributed as well as possible, taking into account the axial
thermal expansion. The Anti friction-bearing machines with
a positioning bearing (standard machine) do not have axial
play.
The machines are delivered with the rotor mechanically
centered (axially and radially) in relation to the stator.
CAUTION :
THE ALIGNMENT STANDARDS OF MANUFACTURERS
OF DRIVE MACHINES ARE FREQUENTLY MORE
PRECISE THAN THOSE OF THE A.C.E.O
b) Axis height Thermal elevation

X
Y

Horaire
Clock Wise

Stop

Anti horaire
Counter Clock Wise

2
1

Clear : diametrical clearance

Oil film : oil film thickness
: Attitude angle
Clear.

X=
Oil film . Sin ( )
2

Clear
Clear

Y =
Oil film . Cos ( )

2
2

d)Anti-friction bearing shaft elevation

Caused by thermal growth of the anti friction bearing.
"2"
Y 0,01 mm

"1"

1 - cold, in rotation, or stopped

2 - hot, in rotation, or stopped

H (mm) = (K-1) . H(m) . T(K)

H(m) = Height of the machine axis
T= frame temperature elevation = 30C
= Coefficient of steel elongation = 0.012 K-1

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SERVICE AND OPERATING MANUAL

ALTERNATORS
4.3.2 Two bearings machine alignment

4.3.3 Single bearing machine alignment

a) machines without axial end play (standard)

The alignment must take the tolerances of the coupling into
account. A misalignment, acceptable by the coupling, must
not create an excess load on the bearing subsequent to the
axial and radial stresses outside the tolerances of said
bearing.

a) General points
The alignment consist also to get the rotor of the
synchronous machine coaxial to its stator

Shafts alignment limits to follow:

Angular error
0.01 mm
100 mm

0.08 mm
parallelism error

To check the alignment, there are different methods: the

"double concentricity" method is described in the
"alignment procedure" chapter 4.3.4.

"A" et "B" give the shaft line alignment

"D" et "E" give the alignment of the stator regarding the
rotor. Because of the engineering of the synchronous
machine the only requested adjustment is "C".

b) machines with axial end play

The alignment must be performed using the same method
as for a machine having no axial end play.

b) Single bearing machine except A56 equipped with

anti friction bearing
applicable to all machines; except A56 equipped with anti
friction bearing

CAUTION:
THE ROTOR AXIAL LOCATION MUST BE CHECKED TO
AVOID ANY MAGNETIC OFFSET

It is imperative to position the rotor axially in relation to the

stator in order to achieve correct magnetic centring of the
rotor in the stator.

CAUTION:
THE FAN THRUST OF THE ELECTRICAL MACHINE
MUST BE HELD THROUGH THE COUPLING.
A needle fitted on the drive end side bearing must face a
groove machined on the shaft. If the needle is missing the
distance "A" (distance from the groove up to the first
bearing part) is stamped on the shaft enabling checking.

Single-bearing machines are delivered by the ACEO

factory with the rotor centered mechanically (axially and
radially) in relation to the stator.
A

Example for a sleeve bearing machine :

B
B
1

Two half-shells (B parts) mounted on the front flange act as

a front bearing for the transportation and installation. The
outside of the centring half-shells face a groove machined
on the shaft.
"A"

The half-shells have "L = L" construction symmetry

The length "A" shown on the diagram is stamped on the
shaft end (allowing alignment in case of absence of item
"B" rings or in case of absence of groove on the shaft)
The length "L" shown on the diagram is stamped on the
shaft end.
The side "C" represents the machined side of the bearing.
Remove the centring upper half-shell (upper "B" part).
Fit the electric machine to the drive system centering.

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ALTERNATORS
Remove the centering lower half-shell (lower "B" part).
Carry out the alignment by moving the machine assembly
by means of lifting-screws mounted on the brackets (see
alignment procedure below). Use shims in order to obtain
proper alignment.
The centering of the rotor in relation to the stator should be
checked by measuring the concentricity of the shaft in
relation to the bearing. After having tightened the fastening
screws completely, the rotor-stator alignment must be
better than 0.05 mm axis-to-axis (that is 0.1 mm reading).
Shafts alignment limits (regarding the drive):

The centering of the rotor in relation to the stator should be

checked by measuring the concentricity of the shaft in
relation to the end ring of the stator. After having tightened
the fastening screws definitively, the rotor-stator alignment
must be better than 0.05 mm from axis to axis (that is 0.1
mm reading).

A
1
2

Angular error
0.01 mm
0.02 mm
parallelism error

100 mm

Check the axial positioning of the rotor in relation to the

stator. For this verification, use an upturned half-shell ("B"
part) (use of the symmetry of the "L = L" part) as shim. The
outside of the shim ("B" part) must be facing the groove
machined on the shaft to within +/- 1 mm.
Mount the cover plates by replacing the transportation halfshells (delivered separate with the machine) to avoid
foreign matter entering in the machine. Make sure the
closing plates are correctly centered in relation to the shaft.

A
4

1 - Delivered loose
2 - Fan
3 - Positioning groove
4 Shipping bracket
Shafts alignment limits:

c) Single bearing machine A56 Anti friction-bearing,

only
It is imperative to position the rotor axially in relation to the
stator in order to have proper magnetic centring of the rotor
in the stator.
The single-bearing machines are delivered by the ACEO
factory with the rotor centered mechanically (axially and
radially) in relation to the stator.
A false front bearing ("Transportation support") keeps the
rotor mechanically centered during transportation. The rotor
is centered if the groove machined on the shaft coincides
with the inside face of the shipping bracket. The inside
surface of the shipping bracket is in the same plane as the
outside machining of the stator.
The length "A" shown in the diagram is marked by cold
stamping on the coupling armature.

Angular error
0.01 mm
0.02 mm
parallelism error

100 mm

Check that the groove marking machined on the shaft is

opposite the outside face of the stator or respects the
measurement "A" to within + or - 1 mm.
Mount the fan screen on the stator (delivered with the
machine as separate part).
Mount the fan on its hub, whilst respecting the angular
marking (balancing respect).
Fit the front housing.

Slide the fan screen and the fan onto the shaft.
Fit the rotor on the centring of the drive system.
Remove the "Transportation support"
Carry out the alignment by moving the machine assembly
by means of lifting-screws mounted on the pads. Use shims
to obtain correct alignment.

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ALTERNATORS
MEASUREMENTS
4.3.4 Alignment procedure

+ 134

C1

a) Checking "Double concentricity" alignment method

This method is not sensitive to axial movements.(the
alignment methods using axial measure may often be
perturbed by small axial movement of the rotor)

C2

+ 90
+ 70
12h

B
+ 164

It is possible to check the alignment with the coupling

installed.
Equipment required :
Two rigid brackets. The rigidity of the two brackets is very
important.
Two micrometers

+ 86

9h

A
6h

3h
+ 104

+ 102
L=400

+ 100

Implementation :
During the measures, both shafts must turn simultaneously
in the same direction. (For example : the coupling installed
with its screws untightened). By turning both shafts
simultaneously, the measurement is not affected by the
error resulting from run out of the two shaft ends.

Measurements referring to the vertical plane:

Considering the vertical plane "C1" : The vertical action
towards the top of shaft "A" on the micrometer is dominant.
In the plane "C1" the axis "A" is higher than axis "B
( 90 - 100 ) / 2 = - 5
In the vertical plane "C2", the vertical action towards the top
of shaft "B" on the micrometer is greater.

C1
B

12h

In the plane "C2" the axis "B" is higher than axis "A"
( 134 - 102 ) / 2 = 16
The respective position of the axes is as follows:

9h

C1
A

3h

A
16

C2

6h

C2

L
The "C1" and "C2" micrometers are located at an angular
difference of 180.

Regarding the vertical plane the angular alignment error is:

( 16 + 5 ) / 400 = 5.25 % (not acceptable)
Measurements referring to the horizontal axis:

More the distance "L" is long better should be the sensitivity

to detect the angular error

In the plane "C1" the axis "B" is further to the right than "A
( 104 - 86 ) / 2 = 9

The reading should be performed 4 times for the "C1" and

"C2" micrometers : at 12h, 3h, 6h, 9h

In the plane "C2" the axis "B" is further to the left than "A
( 70 - 164 ) / 2 = - 47

It is recommended to record the results and draw the axes

for better evaluation, as explained below. Interpretation of
measurements by means of an example.

The representation of the shafts is as follows:

C1
B

Values given in millimeters. The reading is considered

positive (+) when the micrometer stylus is pushed inwards.

A
47
9

C2

Regarding the horizontal plane the angular error is:

( 47 + 9 ) / 400 = 14 % (not acceptable)
In the both planes the parallelism error is:
5 2 + 9 = 10.3 or 16 2 + 47 = 49.6 (not acceptable)

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ALTERNATORS
4.4 ELECTRICAL CONNECTIONS
4.4.0. General points
The installation must comply with the electrical diagrams.
Refer to the attached the electrical diagrams.
Check that all the protection devices are correctly
connected and in good working order.
For low-voltage machines, power supply cables must be
connected directly to the machine terminals (without adding
washers etc)
For high-voltage machines, power supply cables should be
connected to separate terminals or to current transformer
terminals.
NOTE:
THE GLAND PLATE IS MADE OF NON MAGNETIC
MATERIAL.
CAUTION
DO NOT ADD WASHERS TO THE POWER SUPPLY
CABLE TERMINALS OTHER THAN THOSE USED BY
THE MANUFACTURER OF THE ELECTRIC MACHINE
Check that the lugs are tightened.

4.4.1. Phase-sequence
a) Standard units ; IEC 34-8
Except by special request of the customer, the phasesequence is carried out using the IEC 34-8 standard. An
arrow located on the front bearing indicates the direction of
rotation.
In the terminal box a specific marking plate indicates the
specific generator phase sequence.
Clockwise rotation viewed
from the shaft drive end

Counter clockwise rotation

viewed from the shaft
drive end

The phases are marked:

U1, V1, W1.

The phases are marked:

U1, V1, W1.

Viewed from the front of

the terminal box the
terminals are :
U1, V1, W1

Viewed from the front of

the terminal box the
terminals are :
U1, V1, W1

The installer connects :

The installer connects :

L1 --> U1
L2 --> V1
L3 --> W1

L3 --> U1
L2 --> V1
L1 --> W1

CAUTION
ALL CURRENT TRANSFORMERS MUST BE
CONNECTED
CAUTION
THE INSTALLED POWER CABLES MUST BE FIXED
AND SUPPORTED IN SUCH A WAY AS TO BE ABLE TO
WITHSTAND THE VIBRATION LEVEL REACHED BY
THE GENERATOR IN OPERATION (refer to Vibration
chapter)
The power cables must not stress (push, pull, bend ...) the
generator terminals

U2

V2

W2

U2

V2

W2

U1

V1

W1

U1

V1

W1

L1

L2

L3

L3

L2

L1

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SERVICE AND OPERATING MANUAL

ALTERNATORS
b) On request ; NEMA
An arrow located on the front bearing indicates the direction
of rotation.
In the terminal box a specific marking plate indicates the
specific generator phase sequence.
Counter clockwise rotation
viewed from the stator
connection (NEMA)

Clockwise rotation viewed

from the stator connection
(NEMA)

(Clockwise rotation viewed (Counter clockwise

rotation viewed from the
from the shaft drive end
shaft drive end following
following IEC)
IEC)
The cables are marked:
U1, V1, W1.

The cables are marked:

U1, V1, W1.

4.4.2 Insulating distances

Products not delivered by ACEO and then installed in the
terminal box must meet the electrical insulating distances.
This applies to power cables and lugs, and to added
transformers, etc.
Nominal Voltage

500 V

1 KV

2 KV

3 KV

Phase-Phase in
the air (mm)

25

30

40

60

Phase-Earth in the
air (mm)

25

30

40

60

Phase-Phase
Creeping (mm)

25

30

40

70

Phase-Earth
Creeping (mm)

25

30

40

70

The terminals are marked : The terminals are marked :

T3, T2, T1
T3, T2, T1
Viewed from the front of
Viewed from the front of
the terminal box the cables the terminal box the cables
are :
are :
U1, V1, W1
U1, V1, W1

Nominal Voltage

5 KV

7,5KV 12,5KV

15 KV

Phase-Phase in
the air (mm)

120

180

190

190

120

125

125

The installer connects :

Phase-Earth in the
air (mm)

90

The installer connects :

L1 --> (U1) T3
L2 --> (V1) T2
L3 --> (W1) T1

L3 --> (U1) T3
L2 --> (V1) T2
L1 --> (W1) T1

Phase-Phase
Creeping (mm)

120

180

190

190

Phase-Earth
Creeping (mm)

120

180

190

190

T6

T5

T4

T6

T5

T4

4.4.3 Added products in the terminal box

This may apply to site added customer CTs ; VTs etc.
ACEO must be informed if some appliances have to be
installed in the generator terminal box.

U1

V1

W1

U1

V1

W1

T3

T2

T1

T3

T2

T1

L1

L2

L3

L3

L2

L1

The products not delivered by ACEO and then installed in

the terminal box must meet the electrical insulating
distances. Refer to chapter 4.4.2.
The installed appliances must be able to withstand
vibration.

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ALTERNATORS
5. START-UP
5.0 START-UP SEQUENCE
The generator start up (commissioning) must follow the
following sequences:
5.0.1 Static checks
Machine fixing as per chapter 5.2
Alignment as per chapter 5.2
Cooling as per chapter 5.2
Bearing lubrication as per chapter 5.2
Electrical connections as per chapter 5.1.0 and chapter
5.1.2
Winding insulation as per chapter 6.3.2
5.0.2 Rotating checks
a) Rotating checks not excited
Run the generator without excitation by steps to verify the
bearings temperature as per chapter 5.2
At the nominal speed (not excited) measure the vibrations.
Check that the vibration level is in accordance with the
generator (as per chapter 5.2.1) and duty request.
b) Rotating checks at no load excited
In AVR manual mode; Voltage adjustment; check the
excitation current value (refer to AVR manual and to the
generator test report)
In AVR automatic mode; Voltage adjustments; Voltage
range; check the excitation current value (refer to AVR
manual and to the generator test report)
At the nominal speed (excited) measure the vibrations.
Check that the vibration level is in accordance with the
generator (as per chapter 5.2.1) and duty request.
c) Generator and site safeties
proceed to the site safeties adjustment (over voltage relay,
over current relay, differential protection; negative
sequence relay...). The setting points are not under our
responsability.
Check the synchronizer setting following chapter 5.1.3
d) Rotating checks at full load
Operating In parallel with the mains
Adjust the Power Factor
Load the generator step by step. :
Check the excitation current at 25%of the rated load
Check the excitation current at 100%of the rated load
At the nominal speed (full load) measure the vibrations.
Check that the vibration level is in accordance with the
generator (as per chapter 5.2.1) and duty request.

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ALTERNATORS
GENERATOR START UP CHECK LIST

5.0.3

TYPE

SERIAL N

Voltage
Output Power

Frequency

Hz

kVA

Speed

rpm

Power Factor

STATIC CHECKS
Mechanical checks

Direction of Rotation
Clock Wise
or
Anti-clock Wise
Mechanical Fixing of the generator
______________________________________________________
Coupling - Alignment to the engine
______________________________________________________
Cooling :
Coolant flow and level
______________________________________________________
Air inlet and exhaust free ______________________________________________________
Bearing lubrication : Sleeve Bearings Lubrication (flow ; level ; oil type)
________________________
or
Anti-friction Bearings Greasing
Temperature sensors (correct readings)
_______________________________
Space Heaters
____________________________________________________________________

Type of AVR :

1F

2F

3F

Electrical connections between alternator, AVR and main panel :

Output power cables connections following phase order ___________________________________________

Terminal box connections
___________________________________________
AVR detection voltage
___________________________________________
Supply power and excitation terminals
___________________________________________
Network detection (3F only)
___________________________________________
Command signals (equalisation and synchronisation for 2F and 3F)
_________________________________
Excitation polarity and booster
___________________________________________
Protective devices : (Bearing oil level fault detectors; Temperature sensors, etc) __________________
External accessories (e.g.. remote potentiometer)
___________________________________________

ALL CURRENT TRANSFORMERS MUST BE CONNECTED

Windings insulation

Insulation test of the :

Stator
Measured values in MOhms :

Rotor

Exciter armature

Exciter field

All works must be carried out by a qualified and authorized person.

For more information, please refer to the service manual

Tested by :

Date & Signature :

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ALTERNATORS
ROTATING CHECKS
WITH EXCITATION - AT NO LOAD CONDITIONS
Verification of the bearings temperature

In manual mode :

Voltage adjustment
Excitation current check

___________________________________
___________________________________

In automatic mode :

Voltage Setting (referring to nominal voltage)

________________________
Excitation current check
___________________________________

_________________________

Parallel coupling : Adjustment to parallel operation (3F)

________________________

A FAULTY SYNCHRONISING CAN BE THE ORIGIN OF DAMAGES (HIGH MECHANICAL OVERTORQUE)

Maximum acceptable values for synchronisation to the mains :
Maximum frequency shift
0,1 Hz
_________________________
Maximum Phase offset
10
_________________________
Maximum voltage (P.N.) difference
5% of Un
_________________________

Control / Adjustment of the site safeties

Over-voltage,
_________________________________________________________________
Over-current (by short-circuit on stator in separate excitation mode),
_________________________
Negative sequence relay, _________________________________________________________________
Over-speed,
__________________________________________________________________
Differential protection (in static conditions),
_____________________________________

Other protective device. __________________________________________________________________

CHECK THAT ALL SAFETY EQUIPMENT OPERATES CORRECTLY

WITH EXCITATION - LOADED

Voltage stability

__________________________________________________________________

Adjustment of the Power Factor

____________________________________
Verification of the excitation current versus load from 25% to full load at rated PF.
_______________
Maximum load value
kVA
PF

Vibrations measurements in :
mm/s RMS.
At nominal speed measure the vibrations
Drive End
H
V
Non Drive End
H
V

or

other unit
A
A

All works must be carried out by a qualified and authorized person.

For more information, please refer to the service manual

Tested by :

Date & Signature :

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ALTERNATORS
c) Parallel coupling

5.1 ELECTRICAL START-UP INSPECTION

5.1.0 General points
Electrical connections (auxiliaries, safeties and power
connections) must comply with the diagrams provided.
Refer to chapter 4
DANGER:
CHECK THAT ALL SAFETY EQUIPMENT OPERATES
CORRECTLY.
5.1.1 Winding Insulation
The insulation and the polarization index must be
measured on start up.
To measure the insulation refer to the chapter.6.3.2
5.1.2 Electrical connections
The phases must be connected directly to the machine
links (with no spacers or washers, etc).

CAUTION:
AN IMPROPER COUPLING CAN BE THE ORIGIN OF
DAMAGES (HIGH MECHANICAL OVERTORQUE)
At the coupling the following values must not be overpass:
Max frequency shift :

0,1 Hz

Max phase offset :

10 (electrical angle)

Max voltage (phase - neutral) between machines :

(at phase offset =0)
5 % of the nominal voltage
In case of faulty coupling, of mains desapearing followed by
a mains come back inducing a faulty coupling over what it
is acceptable by the generator, ACEO cannot be
considered as responsable of the damages.

5.2 MECHANICAL START-UP INSPECTION

5.2.0 General points

Make sure that the lugs are sufficiently tightened.

a) Alignment ; fixing ; prime mover

The installation must comply with the manufacturers
installation rules for drive machine (alignment, mounting).

CAUTION:
ALL CURRENT TRANSFORMERS MUST BE
CONNECTED

An arrow at the drive end, end shield, indicates the

direction of rotation.

5.1.3 Parallel operation

a) Definition of parallel operation
Between machines
Parallel operation is possible if the power ratio between the
smallest machine and the largest machine is less than or
equal to 10.
With the mains
The "mains" is defined as a source of power greater than or
equal to ten times the output of the machine with which it
will be coupled.
b) Possibility of parallel operation
Parallel operation, if planned at the outset, does not cause
any problems if several basic rules are followed.

b) Cooling
The air inlet and exhaust must be unobstructed.
The cooling auxiliaries (water circulation in the cooler, etc)
must be operating.
c) Lubrication
Lubrication must be carried out :
- anti friction bearings, refer to chapter 2.3
- Sleeve bearings, refer to chapter 2.4
5.2.1 Vibrations
The vibration measurement must be taken on each bearing
in the three directions. The measured levels must be lower
than the specified values indicated in the chapter 2.1.3
Adjust the sensor as per chapter 2.1.3

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ALTERNATORS
6. PREVENTIVE MAINTENANCE
6.1 MAINTENANCE SCHEDULE
The purpose of the general maintenance schedule below is to help establish the maintenance schedule particular to the
installation. The suggestions and recommendations are to be followed as closely as possible in order to maintain the machine
efficiency and in order not to reduce the service life of the machine.
The maintenance operations are detailed in the chapters relative to the subjects concerned (Example: bearing, see chapter 2).
LUBRICATION AND PREVENTIVE MAINTENANCE SCHEDULE
Frequency of maintenance
Days
STATOR
Winding temperature

Hours

Comments

Refer to 2.1.3

Bolts tightening

8000

Refer to 6.2.2

Cleaning air inlet and outlet

1000

Refer to 6.2.3

Insulation

8000

Refer to 6.3.2

Polarisation index

8000

Refer to 6.3.2

ROTOR
Insulation

8000

Refer to 6.3.2

Cleaning diodes

8000

Refer to 7.4

Diodes tightening

8000

Refer to 2.2.4

Polarisation index

8000

Refer to 6.3.2

TERMINAL BOX
Cleaning

8000

Regulator assembly

8000

Applicable if mounted in the terminal box

Bolts tightening

8000

Refer to 6.2.2

Following technical specification in "Section 1"

SLEEVE BEARINGS
Oil leak

Refer to 2.4.9

Oil temperature

Refer to 2.4.10

Oil level

Refer to 2.4.5

Oil drain

8000/16000 Following environment cleanness; Refer to 2.4.5

Bolts tightening

8000

Following technical specification in "Section 1"

ANTI FRICTION BEARINGS

Re greasing
Bearing temperature

Refer to 2.4

Refer to 2.3.3 ; See lub plate; grease at least every 6 months

1

Refer to 2.3.5

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ALTERNATORS
LUBRICATION AND PREVENTIVE MAINTENANCE SCHEDULE (following)
Jours

Heures

Commentaires
Following technical specification in "Section 1"

COOLER
Leakage level

Refer to 2.7.4

Water temperature

Refer to 2.7.4

Cleaning

Refer to 2.7.2 ; following site condition

FILTERS
Cleaning

Following technical specification in "Section 1"

1000

Following technical specification in "Section 1"

FAN-MOTOR
Bearing Re greasing
PROTECTION DEVICES

Refer to 2.8 & following " Section 1"

Refer to motor lub plate ; following" Section 1"

8000

Refer to 2.19 et "Section 1 ; (sensors, , .)

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ALTERNATORS
6.2 MECHANICAL MAINTENANCE
To obtain additional information on the maintenance of subassemblies, refer to the chapters dealing with the subassemblies concerned.
6.2.1 Air gap check
a) Double bearing machine
Verification of the air gap is not necessary. The rotor is
mechanically centered by its construction. Even after
dismantling and reassembling the machine, the rotor will
return to its position without verification of the air gap.
b) Single bearing machine
When the machine is delivered, the rotor is mechanically
centered in the stator (see chapter on alignment). After
dismantling the machine, it will be necessary to center the
rotor in the stator, by using the two half-shells (delivered
with the machine) as explained in the chapter 4.3.3.
If you do not have 1/2 shells, use a dial indicator to check
the concentricity between the shaft (machined surface) and
the front bearing (machined surface).
6.2.2 Bolts tightening
Check the tightening of the sleeve bearing fixing bolts (refer
to chapter 2.4)
Check the tightening of the rotating diodes (refer to chapter
2.2.4)

6.2.3 Cleanliness
The whole machine must be kept clean.
CAUTION :
ALL THE CLEANING PERIODS INDICATED IN THIS
MANUAL MAY BE CHANGED (INCREASED OR
DECREASED) ACCORDING TO SITE CONDITIONS
The air inlet and air outlet surfaces must be maintained
clean (Louvers can be cleaned as per the filters) refer to
chapter 2.8.
CAUTION :
DIRT ENTERING THE MACHINE MAY POLLUTE AND
THUS REDUCE THE ELECTRICAL INSULATION
The rotating diodes must be keep clean. The rotating
diodes cover has to be clean. Refer to chapter 7.4

6.3 ELECTRICAL MAINTENANCE

6.3.1 MEASURING INSTRUMENTS
a) Instruments used
- AC voltmeter 0-600 Volts
- DC voltmeter

0-150 Volts

- Ohmmeter

10E-3 to 10 ohms

- Megohmmeter 1 to 100 MOhms / 500 Volts

Check the tightening of the terminal box accessories (refer

to chapter 2.18)

- AC Ammeter

0- 4500 A

- DC Ammeter

0-150 A

If no torque value is specified into the concerned chapter

the following values can be used

- Frequency meter 0-80 Hz

Bolt : Steel / Steel

(greasy thread)
nominal
(mm)

Torque
(mN)

nominal
(mm)

Torque
(mN)

3
4
5
6
8
10
12
14
16

1,16
2,66
5,2
9,1
22
44
76
121
189

18
20
22
24
27
30
33
36

261
370
509
637
944
1280
1739
2232

Low resistance can be measured by means of an

appropriate ohmmeter or by using a Kelvin or Wheatstone
bridge.
NOTE :
The identification of the equipment polarity may differ from
one ammeter to another.

52

LEROY SOMER

SERVICE AND OPERATING MANUAL

2327 en 02.2006 / k

ALTERNATORS

Volts

10

b) Identification of ohmmeter polarity

In many testing procedures, the ohmmeter polarity is
important (diode test, etc) and must be known. As a second
instrument, you must use a voltmeter in the "direct current"
position, in order to check the polarity of the ohmmeter
connections. Proceed as explained below :

Ohms

DC

The measurement has to be taken between one phase and

the earth.
Machine nominal voltage

Applied test
voltage (DC)

Un 2400 V

Un > 2400 V

500 V DC

1000 V DC

[3 (U n + 1)] M

The measured value at 25C must be over

where Un (the nominal voltage) is in Kilovolts. (e.g. : a
generator of 6.6 KV must have an insulation resistance
greater than 22.8 M).
If the minimum insulation level is not reached, dry the
windings (refer to chapter 7.5)
c) Field insulation measurement
Disconnect the two ends of the field at the rotating diodes
bridge

6.3.2 Insulation check of the winding

a) General
The insulation resistance enables the status of the machine
insulating to be verified.
The following measurements can be taken at any time
without any damage to machine insulating material.
The insulation check must be done :
Before the start up
After a long standstill
As soon as an abnormal operation occurs.
If the measurement indicates a poor result we advise
contacting our Service department.
To perform the measurement the generator must be
stopped.

The measurement should be taken between one end of the

field winding and the earth.
The applied test voltage must be of 500 V DC.
The measured value must be over 20 M.
If the minimum insulation level is not reached, dry the
windings (refer to chapter 7.5)
d) Exciter insulation measurement
CAUTION
ALL ACCESSORIES MUST BE DISCONNECTED (AVR ,
EMC FILTER ;;;)
REFER TO THE ELECTRICAL DIAGRAM TO IDENTIFY
THE ACCESSORIES TO DISCONNECT

If the resistance is less than that required, it is necessary, if

possible, to dry the machine (refer to chapter 7.5).

To measure the exciter field insulation disconnect the two

ends of the exciter field at the terminals located on the top
of the exciter.

b) Armature insulation measure

Disconnect the three phases at the generator terminals.

To measure the exciter armature insulation disconnect the

two ends of the exciter armature at the rotating diodes
bridge

CAUTION
ALL ACCESSORIES MUST BE DISCONNECTED (AVR ,
EMC FILTER ;;;)
REFER TO THE ELECTRICAL DIAGRAM TO IDENTIFY
THE ACCESSORIES TO DISCONNECT

The measurement should be taken between one end of the

field winding and the earth.
The applied test voltage must be of 500 V DC.
The measured value must be over 20 M.
If the minimum insulation level is reached, dry the windings
(refer to chapter 7.5)

53

LEROY SOMER

SERVICE AND OPERATING MANUAL

2327 en 02.2006 / k

ALTERNATORS
e) Polarization index
The polarization index enables the status of the machine
insulating to be verified and gives an indication of the
pollution of the winding.
A poor polarization index may be corrected by a cleaning of
the winding
The following measurements can be taken at any time
without any damage to the machine insulating material.
CAUTION
ALL ACCESSORIES MUST BE DISCONNECTED (AVR ,
EMC FILTER ;;;)
REFER TO THE ELECTRICAL DIAGRAM TO IDENTIFY
THE ACCESSORIES TO DISCONNECT
NOTE:
It must be done using a stable DC source.
Use a specific polarization index appliance under 500 or
1000 DC volts (refer to" insulation of the winding" chapter
for the correct applied voltage)

7. SERVICING
7.1 GENERAL SERVICING
DANGER :
BEFORE WORKING ON THE GENERATOR, MAKE
SURE THAT THE START-UP CANNOT BE ACTIVATED
BY ANY MANUAL OR AUTOMATIC SIGNAL
DANGER:
BEFORE WORKING ON THE MACHINE, MAKE SURE
THAT YOU HAVE UNDERSTOOD THE OPERATING
PRINCIPLES OF THE SYSTEM. IF NECESSARY, REFER
TO THE APPROPRIATE CHAPTERS IN THIS MANUAL.
CAUTION:
GIVEN THE POWER FACTOR APPLIED TO THE
MACHINE, A VOLTMETER OR KILOWATT METER
DOES NOT NECESSARILY SHOW THE KVA LOAD OF
THE MACHINE.

Open the winding star point

Disconnect AVR cables from the stator terminals

7.2 TROUBLESHOOTING
7.2.0 General points
When a defective part is replaced with a spare part, make
sure that it is in good condition.
7.2.1 Regulator trouble-shooting procedure
Refer to the enclosed regulator manual.

7.3 ELECTRICAL TESTS

Apply the requested voltage
After 1 minute record the Insulating resistance

7.3.1 Stator winding test

See chapter 6.3

After 10 minutes record the Insulating resistance

7.3.2 Rotor winding test
See chapter 6.3
The polarization index must be higher than 2.
Proceed for each phase

7.3.3 Excitation armature winding test

See chapter 6.3
7.3.4 Excitation field winding test
See chapter 6.3
7.3.5 Rotating diode bridge test
See chapter 2.2
7.3.6 Electric panel test
Use electrical diagrams for assistance.

54

LEROY SOMER

SERVICE AND OPERATING MANUAL

2327 en 02.2006 / k

ALTERNATORS
7.4 CLEANING THE WINDINGS
7.4.0 General points
The cleaning of the winding is an heavy service operation
which has to be engaged only if necessary.
The cleaning of the windings become necessary as soon
as the polarization index is not satisfactory (refer to chapter
6.3.2)
7.4.1 Coil-cleaning product
a) General
CAUTION:
SOLVENTS, WHICH ARE HIGHLY CHLORINATED AND
SUBJECT TO HYDROLYSIS IN DAMP ATMOSPHERES
ARE PROHIBITED. THEY QUICKLY BECOME
ACIDIFIED, PRODUCING CORROSIVE AND
CONDUCTIVE HYDROCHLORIC ACID.
CAUTION:
DO NOT USE TRICHLORETHYLENE,
PERCHLORETHYLENE, OR TRICHLORETHANE
Avoid mixtures sold under various trademarks which often
contain white spirit (which evaporates too slowly) or
chlorinated products (which are likely to become acidified).

7.4.2 Cleaning the stator, rotor, excitation system and

diodes
a) using specific chemical product
The insulation and the impregnation system are not
damaged by solvents (see the list of authorized products
above).
It is essential to avoid entry of cleaning agents into the
slots. Apply the product with a brush, sponging frequently in
order to avoid accumulation in the housing. Dry the winding
with a dry cloth. Allow the traces to evaporate before
reassembling the machine.
CAUTION:
AFTER CLEANING THE GENERATOR, DRYING IS
IMPERATIVE TO RECOVER THE CORRECT WINDING
INSULATION
b) Rinsing using soft water
Hot soft water (less than 80C) used under pressure (less
than 20 bars) can be used.
CAUTION:
AFTER CLEANING THE GENERATOR, DRYING IS
IMPERATIVE TO RECOVER THE CORRECT WINDING
INSULATION

CAUTION:
DO NOT USE ALKALINE PRODUCTS. THEY ARE
DIFFICULT TO RINSE AND CAUSE REDUCTION OF
INSULATION RESISTANCE BY FIXING THE HUMIDITY
b) Cleaning products
Use pure de-greasing and volatile agents which are welldefined such as :
Gasoline (without additives)
Toluene (slightly toxic ) ; inflammable
Benzene or benzine (toxic ; inflammable)
Ciclohexaire (non-toxic; inflammable)
Soft water

55

LEROY SOMER

2327 en 02.2006 / k

SERVICE AND OPERATING MANUAL

ALTERNATORS
Check the winding insulation and the polarization index

7.5 DRYING THE WINDING

7.5.0 General points
All electric machines must be stored under dry conditions. If
a machine is placed in damp surroundings, it must be dried
before it is put into service. Units operating intermittently or
placed in areas with high temperature variations, are
exposed to dampness and must be dried very thoroughly if
necessary.

If necessary conduce an other drying period...

U1
U2
V1
W1

W2

DC

7.5.1 Drying method

a) General points
During the drying operation measure the winding insulation
and the polarization index each 4 hours.

V2

A - Stator
B - Rotor
C - Exciter

To survey the insulation progress, record the measured

values and plot the obtained progress function of the time.
When the insulation value becomes constant, the machine
can be considered as dry.
When the resistance is constant, it may be assumed that
the machine is dry. This operation may take up to 24 hours,
depending on the size of the machine and on the degree of
dampness. This may even take up to 72 hours.
CAUTION:
TAKE FIRE-PREVENTION MEASURES DURING THE
DRYING OF THE MACHINE.
ALL THE CONNECTIONS MUST BE TIGHTENED.

7.6 RE-VARNISHING
NOTE:
WHATEVER VARNISH IS USED, NEW VARNISHING IS
NOT RECOMMENDED, SINCE IT TRAPS AND
PERMANENTLY RETAINS THE CONDUCTIVE CARBON
PARTICLES. THE ORIGINAL VARNISHES HAVE A
LONG SERVICE LIFE AND DO NOT NEED TO BE
STRENGTHENED.

b) Drying generator stop

The procedure " Drying generator in rotation" should be
preferred to the following one if it is possible to run the
generator at its nominal speed
Several thermometers must be positioned onto the winding
and the temperature must not exceed 75C (167F). If one
of the thermometers exceeds this value, immediately
reduce the heating effect.
Dry by using an external source of heat, for example,
heaters or lamps.
Leave an opening for an exhaust for the damp air.
c) Drying generator in rotation
Disconnect the machine from the mains
Short circuit the machine stator at the machine terminals
Disconnect the Voltage regulator and short-circuit the
booster.
Install an amp meter on the short-circuited winding.
Run the machine at its nominal speed (to air cool the
machine)
Energized the machine (exciter field) using an separate ex
citation source. Use a DC source (batteries ...)
Adjust the excitation current to get the nominal current at
the stator (machine armature).
Warm up during 4 hours, stop and leave it to cool down
(winding temperature < 50C)

56

2327 en 02.2006 / k

SERVICE AND OPERATING MANUAL

LEROY SOMER

10. Foldout (1.)

ALTERNATORS

sheet 1
Typical cut view A52

Anti friction bearing machine

10

11 12

13

14
15

Rotor

Bearing (drive end)

Fan hub

Drive end shield

Fan

Fan screen

Stator winding

Stator ribs

Stator lamination

10

Polar wheel

11

Balancing disc

12

Exciter field

13

Exciter armature

14

Non drive end shield

15

Bearing (non drive end)

16
17
18

16
2
17
1

10

11

12 13

14

15

16

Rotating resistances

17

Rotating diodes
Diode bridge cover

Sleeve bearing machine

57

SERVICE AND OPERATING MANUAL

LEROY SOMER

2327 en 02.2006 / k

10. Foldout (1.)

ALTERNATORS

sheet 2
Typical cut view A53 et A54

Sleeve bearing machine :

Rotor

Bearing (drive end)

Fan hub

Drive end shield

Fan

Fan screen

Stator winding

Stator ribs

Stator lamination

10

Polar wheel

11

Balancing disc

12

Exciter field

13

Exciter armature

14

Non drive end shield

15

Bearing (non drive end)

16

Rotating resistances

17

Rotating diodes

18

Diode bridge cover

Anti friction bearing machine

59

SERVICE AND OPERATING MANUAL

LEROY SOMER

2327 en 02.2006 / k

10. Foldout (1.)

ALTERNATORS

sheet 3
Typical cut view A56

10

11

12

13

14

Sleeve bearing machine :

Rotor

Bearing (drive end)

Fan hub

Drive end shield

4b

End shield cover

Fan

Fan screen

Stator winding

Stator ribs

Stator lamination

10

Polar wheel

11

Balancing disc

14

Exciter field

13

Exciter armature

14

Non drive end shield

15

Bearing (non drive end)

16

Rotating resistances

17

Rotating diodes

18

Diode bridge cover

15

16

17

Anti friction bearing machine :

61

LEROY SOMER

2327 en 02.2006 / k

SERVICE AND OPERATING MANUAL

10. Foldout (1.)

ALTERNATORS

sheet 4
Typical cut view A58

1
2

Bearing (drive end)

Fan hub

Drive end shield

Fan

Fan screen

Stator winding

Stator ribs

Stator lamination

10

Polar wheel

11

Balancing disc

12

Rotor

Exciter armature

14

Non drive end shield

15

Bearing (non drive end)

16

Rotating resistances

17

Rotating diodes

18

Diode bridge cover

11

12

13

14

15

16

17

Exciter field

13

10

63

LEROY SOMER

SERVICE AND OPERATING MANUAL

2327 en 02.2006 / k

10. FOLDOUT (2.4)

ALTERNATORS

sheet 1
Sleeve bearing

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27

Top half of the housing

Positioning pin hole
Positioning pin
Oil filler hole
Top sight glass
Eye bolt
Screw
Screw
Tap hole ( in the top and bottom halves of the shell, up size 14 )
Machine seal
Top half of the shell
Split line screw - bearing housing
Bottom half of the shell
Spherical seating
Engraved number - bearing shell
Recess
Tap hole
Screw
Split line screw - bearing shell
Engraved numbers - bearing housing
Bottom half of the housing
Connection hole for temperature measurement of the journal part
Oil sight glass
Connection hole for the oil sump temperature measurement
Out/Inlet cooling water (Type E.T..)
Oil cooler ( Type E.T..)
Oil drain plug

65

Flanged , self lubricated

LEROY SOMER

SERVICE AND OPERATING MANUAL

2327 en 02.2006 / k

10. FOLDOUT (2.4)

ALTERNATORS

sheet 2
Sleeve bearing

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

Top half of the housing

Positioning pin hole
Positioning pin
Connection hole for the thrust part oil supply (optional)
Top sight glass
Eye bolt
Screw
Screw
Tap hole ( in the top and bottom halves of the shell, up size 14 )
Machine seal
Top half of the shell
Split line screw - bearing housing
Bottom half of the shell
Spherical seating
Engraved number - bearing shell
Recess
Tap hole
Screw
Split line screw - bearing shell
Engraved numbers - bearing housing
Bottom half of the housing
Connection hole for temperature measurement of the journal part
Oil inlet connection hole
Connection hole for the oil sump temperature measurement
Out/Inlet cooling water (Type E.T..)
Oil cooler ( Type E.T..)
Oil drain plug
Metal tabs ( optional for EFZL. )
Oil outlet connection hole
Oil outlet pipe
Marking

67

Flanged , forced lubricated

LEROY SOMER

Service & Operating Manual

ALTERNATORS
Automatic Voltage Regulator

SECTION 4

Automatic Voltage Regulator

SECTION 4

4009 en 01.2006 / a

GS
3

ou

GS
3

GS
3

or

or

AVR

AVR

AUTOMATIC VOLTAGE REGULATOR

R630
Instruction manual

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

NOTE
THE ELECTRICAL CONNECTION DIAGRAM ARE ONLY GIVEN
AS AN INDICATION. PLEASE REFER TO THE SPECIFIC DIAGRAMS
OF YOUR ALTERNATOR

WARNING
TO PREVENT PERSONNAL INJURY OR EQUIPMENT DAMAGE,
ONLY QUALIFIED TECHNICIANS/OPERATORS SHOULD
INSTALL AND OPERATE THIS DEVICE

CAUTION
MEGGERS AND HIGH POTENTIAL TEST EQUIPMENT MUST NOT BE
USED. INCORRECT USED OF SUCH EQUIPMENT COULD
DAMAGE THE SEMICONDUCTORS CONTAINED IN THE AVR

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

TABLE OF CONTENT
TABLE OF CONTENT
CARDS REFERENCE

GENERAL DESCRIPTION

MIMIC DIAGRAM EXCITATION REGULATION Shunt + Booster

MIMIC DIAGRAM EXCITATION REGULATION AREP

MIMIC DIAGRAM EXCITATION REGULATION PMG

CONNECTICS

GENERATOR / MAINS I/O (1F / 2F)

13

SUPPLY CARD

16

SENSING CARD

18

PID, LIMIT CARD

20

DRIVER CARD

23

COS KVAR OPTIONAL CARD

26

GENERATOR / MAINS I/O (3F) OPTIONAL CARD

29

DIGITAL POT U / P.F OPTIONAL CARD

32

MANUAL MODE 2 OPTIONAL CARD

35

MAINS P.F REGULATION OPTIONAL CARD

38

LIMIT I STATOR OPTIONAL CARD

44

START - UP

46

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

CARDS REFERENCE

CARDS REFERENCE
DESIGNATION

N printed

N Card

REMARKS

Wired empty rack

C51950267

AREP

Wired empty rack

C51950250

Shunt + Booster

Wired empty rack

C51950251

PMG

Generator I/O board

C51950200

100 / 120V - 50 / 60Hz

Generator I/O board

C51950202

400 / 450V - 50 / 60Hz

3F Mains I/O board

C51950220

Alt:110V; rseau:110V

3F Mains I/O board

C51950222

Alt:400V; rseau:400V

2F Mains I/O board

C51950210

1F Mains I/O board

C51950215

Circuit board

Rack supply

CP1950040

C51950041

Sensing

CP1950050

C51950051

PID, limitation

CP1950060

C51950061

Driver

CP1950070

C51950071

Digital U / PF potentiometer

CP1950110

C51950111

Cos, KVAR

CP1950080

C51950081

Manual mode

CP1950100

C51950101

Digital Ifield pot & follower

CP1950110

C51950141

Mains PF regulation

CP1950120

C51950121

Limit I stator

CP1950090

C51950091

= Basic
= Optional
NOTE :
- 1F = Solo or parallel operation between machines (Voltage regulation + reactive load sharing (droop))
- 2F = 1F + parallel operation with the mains (P.F or KVAR regulation)
- 3F = 2F + automatic voltage matching between the generator and the mains. (For synchronizing)

IMPORTANT : The informations given on this sheet will be used to order spare parts. Take care of it.

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

GENERAL DESCRIPTION

GENERAL DESCRIPTION
1) APPLICATION

5) SPECIFICATIONS :

- The AVR model R600 can be used with brushless selfexcited type generators, "SHUNT", "SHUNT with BOOSTER"
or "PMG" or AREP excitation. In case of "SHUNT with
BOOSTER the booster current is totally monitored by the
AVR.
- The AVR is able to ensure, depending of its constitution,
solo operation, parallel operation between equivalent
generators or parallel operation with the mains with cos or
KVAR regulation.

Sensing voltage
: 100/110Vac 50Hz
: 120/130Vac 60Hz
: 380/420Vac 50Hz
: 430/450Vac 60Hz

Power supply
(maximum 180Vac 50/60Hz)
Shunt+Booster = power transformers
AREP = auxiliary windings
PMG = external generator

- The AVR model R630 is composed of electronic cards which

are included in a rack 19" .
- Except the necessary Generator I/O, the optional mains
I/O located on the left of the rack and the driver card
located on the right, all the other cards can be plugged
anywhere in the rack. Future optional cards could be added
without any internal wiring modification.
- The rear flat cable (BUS 64 points) is given more long as it
can be connected to an optional interface terminal block
which gives all the internal test points or in the future the
possibility to connect another rack if the cards number will
become too important.

Field output
: 12 Amperes nominal, 24Amp maximum during 10s on
6 minimum

Accuracy
: +/-1% of the means of the three phases on linear load
and without droop

Voltage setting range

: +/-5% of the nominal voltage by means of external
optional potentiometer .

Droop setting range

: - 7% of the nominal voltage at cos =0

3) INTERCONNECTIONS

Under-frequency protection
: Adjustable threshold and slope from V/Hz to 2V/Hz

Field ceiling
: 110% of If nominal permanently, unlocked in case of
voltage decrease

Protection
: Heat sink overheating, exciter short-circuit

Alarm output
: Heat sink overheating, too much ceiling unlocked time

Environment
: Maximum ambient temperature -10C to +50C
: Fitting in control panel without excessive vibrations

2) DESCRIPTION

- External interconnections are located on the top of the rack

in form of two terminal blocks:
- A power / voltage terminal block (19 terminals, two with
fuses )
- A command / control terminal block (41 terminals)
- A conventional wiring connect this terminal blocks to the
power block fitted on a heat sink and also to the "generator
I/O" and "mains I/O" to give an interface with the flat cable
BUS 64 points.
- In the same manner a 8 points connector connects directly
the driver card to the power block.

4) OPTIONAL CARDS
- Basically the AVR allows voltage regulation with reactive
sharing when paralleling with other machines.
The following cards can be plugged into the AVR without
internal wiring modification :
- Cos / KVAR regulation (2F) (// with the mains)
- Voltage equalisation with the mains (3F) (Synchro)
- Voltage and P.F digital potentiometers
- Manual operation
- I stator limitation
- Mains P.F or KVAR regulation from 4-20mA converter.

6) SCHEMATICS AND DRAWINGS

- Following schematics give all the usual information on the
interconnections between the terminal block, the I/O
connectors and the power block.

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

MIMIC DIAGRAM EXCITATION REGULATION Shunt + Booster
3 booster
CT

parallel
running CT

P.F converter
4-20mA

GS
3
MAINS
2 or 3
measure VT
Out of
supply

2 or 3
measure VT

Power
VT
Optional
Booster
board

or

De-energizing

or
(Power)

(Control)

Mains measure
Out of supply

A VR
Rotating
diode
failure
detector
(OPTION)

Command
inputs

Alarm output

Fault output

Potentiometer
inputs

POWER TERMINALS
Power supply
Power supply

19
5
4

- Field flash

18

+ Field flash

17

+ Field

17 18 19

Power supply

+VDC
Power su pply

Free
wh eeli ng
dio de

+
HALL 8
se nsor 5

- Field

60
+15

LEM
Card

Thermocontact

60

-15
M

C2
B
63

G2

1 2 3 4 5 6 8 7
To LMI 8 points connector
on driver card

E2

70

8
OVDC
Power su pply

8
7

69

5
6

Connec tor LMI 8 pts

ON HEATSINK

P4
9c 10c
To 32 points connector
P4 on "MAINS I / O"

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

MIMIC DIAGRAM EXCITATION REGULATION AREP

parallel
running CT

P.F converter
4-20mA

GS
3
MAINS
AREP windings

2 or 3
measure VT
Out of
supply

2 or 3
measure VT

or

De-energizing

(Power)

(Control)

Mains measure
Out of supply

A VR
Rotating
diode
failure
detector
(OPTION)

POWER TERMINALS
Power supply
Power supply

19
5
4

- Field flash

18

+ Field flash

Potentiometer
inputs

17

+ Field

17 18 19

Power supply

Command
inputs

Alarm output

Fault output

+VDC
Power su pply

Free
wh eeli ng
dio de

+
6
+15

LEM
Card

G2

2 3 4

5 6

8 7

P4

To LMI 8 points connector

on driver card

E2
OVDC
Power su pply

8
7

Thermocontact

60

C2
B
63

Connec tor LMI 8 pts

ON HEATSINK

60

-15
M

70

69

- Field

HALL 8
5
se nsor

9c 10c

To 32 points connector
P4 on "MAINS I / O"

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

MIMIC DIAGRAM EXCITATION REGULATION PMG
TERM INAL BOX

LOAD

parallel
running CT

P.F 4-20mA
converter
MAINS

GS

PMG

2 or 3 measure

2 measure

or

De-energizing

(Power)

(Control)

Mains measure
Out of supply

A VR
Mains P.F measure
Out of supply

Rotating
diode
failure
detector
(OPTION)
Command
inputs
Fault output

Potentiometer
inputs

Alarm output

POWER TERMINALS

Power supply
Power supply

+ Field

17 18 19

Power supply

17
18
19
+VDC
Power su pply

Free
wh eeli ng
dio de

+
HALL
8
se nsor 5

- Field

Thermocontact

60

60
+15

LEM
Card

-15
M

C2
B
63

G2

1 2 3 4 5 6 8 7
To LMI 8 points connector
on driver card

E2

70

8
OVDC
Power su pply

8
7

69

5
6

Connec tor LMI 8 pts

ON HEATSINK

P4
9c 10c
To 32 points connector
P4 on "MAINS I / O"

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

CONNECTICS
CONNECTICS
TERM N
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

VOLTAGE / POWER TERMINAL BLOCK

Phase 1 (U) machine (measure)
Phase 2 (V) machine (measure)
Phase 3 (W) machine (measure)
+ field flashing or pre-excitation input (optional)
+ field output
- field output
+ booster input (nothing if AREP or PMG)
booster input (nothing if AREP or PMG)
Paralleling CT phase 2 (V) S1
Paralleling CT phase 2 (V) S2
Not connected
Phase 1 (U) mains (measure)
Phase 2 (V) mains (measure)
Phase 3 (W) mains (measure)
Nothing in Shunt or auxiliary supply in AREP & PMG
auxiliary supply
auxiliary supply in Shunt or power supply in AREP&PMG
Power supply (CB in AREP and PMG)
Power supply (fuse in Shunt or CD in AREP and PMG)
COMMAND / CONTROL TERMINAL BLOCK
20,20,20
Potentiometer shield (3 terminals)
21
External voltage potentiometer maximum CW)
22
External voltage potentiometer (10K-2W) (cursor)
23
External voltage potentiometer ( minimum CCW)
24
External voltage input (10Vdc, 0V to terminal 20)
25
Field current measurement output (+Vdc)
26
Field current measurement output (0V)
27
External cos potentiometer (CW maximum)
28
External cos potentiometer (10K-2W) (cursor)
29
External cos potentiometer (CCW minimum)
30
External KVAR potentiometer (CW maximum)
31
External KVAR potentiometer (10K-2W) (cursor)
32
External KVAR potentiometer (CCW minimum)
33
cos regulation command input
34
cos regulation command input
35
Voltage equalization command input
36
Voltage equalization command input
37
Overheating or ceiling unlocked time alarm (common)
38
Overheating or ceiling unlocked time alarm output (NC)
39
Overheating or ceiling unlocked time alarm ouput (NO)
40
External +24Vdc supply input (relay locking)
41
External 24Vdc supply input (relay locking) common
42
Upper command voltage and PF
43
Lower command voltage and PF
44
Common
45
Upper command I field (manu)
46
Lower command I field (manu)
47
"AUTO / MANU" command input (Open = "AUTO")
48
"AUTO / MANU" command input (Open = "AUTO")
49
"AUTO / MANU" image output
50
"AUTO / MANU" image output
51
I field direct manual setting potentiometer
Manual mode 1 card I field setting potentiometer (10k)
52
"Cos / KVAR" selection command input (/ terminal 48) (open = "Cos")
53
1F = // running between machines

0F
N
N
N
O
N
N
O
O

1F
N
N
N
O
N
N
O
O
N
N

2F
N
N
N
O
N
N
O
O
N
N

N
N
N

N
N
N

N
N
N

O
O
O
O
O
O
O

O
O
O
O
O
O
O

O
O
O
O
O
O
O
O
O
O
O
O
O
N
N

O
O
O
O
O
O
O
O
O
O
O
O
O
O
O

O
O
O
O
O
O
O
O
O
O
O
O
O
O
O

O
O
O
O
O
O
O
O
O
O
O
O
O
O
O

3F
N
N
N
O
N
N
O
O
N
N
N
N
N
N
N
N

O
O
O
O
O
O
O
O
O
O
O
O
O
N
N
N
N
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O

= Optional

2F = 1F + // running with the mains

= Necessary

3F = 2F + voltage matching before coupling

Nothing

= Not Appliable

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

CONNECTICS
- The following tables give interconnections between each card and the 64 points flat cable.
- Grey cases give signals origine .
- Other cases where they go.
- On the left we have two numbers :
- First the connector numering
- Second test block terminal number.
- On the right we have a recapitulative of all the informations wich can be found on the test terminal block.

10

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Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

CONNECTICS

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LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

OUTLINE
OUTLINE
Configuration SHUNT + Booster

Configuration PMG ou AREP

12

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LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

GENERATOR I/O

GENERATOR / MAINS I/O (1F / 2F)

- The interface input relays between command / control
terminals and internal circuits.
- The interface between 64pts BUS and the analogic input
/ output terminals

1) FUNCTIONAL
- This unit is mainly an interface between external
signals and low power electronics.

2) ADJUSTMENTS

- It is composed by :

- None

- The adaptation three phases transformer between

generator input voltages (1F,2F) and measurement
circuits. For 2F a P.F / KVAR card must be fitted in the
AVR

3) INPUT / OUTPUT
- See following table

- The burden resistor of parallel CT.

- The adaptation transformer between input voltage and
low power electronic supplies.
INPUT
TERMINAL

Connector
32 PTS

Type
I/O

Interface

1
1
2
2
3
3
9
10
16
17

15c
15c
13c
13c
11c
11c
16c
10c
1a
1c

measure
alim
measure
alim
measure
alim
measure
measure
alim
alim

transfo tri TP4

transfo TP2
transfo tri TP4
transfo TP1/2
transfo tri TP4
transfo TP1
resistance RTI
ground
transfo TP3
transfo TP3

20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
37
38
39
40
41
42
43
44
45
46
47
48
49
50

10c
7a
3c
6c
3a
4a
10c
5c
8a
6a
12a
4c
5a
14a
2c
7c
9a
10a
2a
2c
14c
13a
2c
12c
8c
15a
2c
9c
11a

Shield
signal
signal
signal
signal
signal
signal
signal
signal
signal
signal
signal
signal
Cmd Input
Cmd Input
Cmd Output
Cmd Output
Cmd Output
ext alim
ext alim
Cmd Input
Cmd Input
common
Cmd Input
Cmd Input
Cmd Input
Cmd Input
Cmd Output
Cmd Output

ground
resistance
direct
resistance
direct
direct
ground
resistance
direct
resistance
resistance
direct
resistance
relay
relay
relay
relay
relay
relay
relay
relay
relay
relay
relay
relay
relay
relay
relay
relay

Connector
26 PTS

Connector
BUS 64 PTS

7a

8c

8a

5
1

9a
7c
4c
4a

1
13
14
15
16
21
1
6
17
23
6
19
23
8

7c
11a
21a
7c
22c
17a
7c
1c
20c
32a
1c
21c
32a
24a

25
25
25

31a
31a
31a

9
10

23a
24c

11
12
7

22a
23c
25a

12
12

23c
23c

VOLTAGE INPUTS :
Reference
Generator sensing voltage
C5 195 0200
100V - 120V 50/60Hz
C5 195 0202
400V - 450V 50/60Hz
13

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LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

GENERATOR I/O

U alt

V alt

W alt

TI / /

10

TI / /- GND

15c

13c

2
3

16c

1
5
R1

Alim aux il
Alim aux il
+24Vdc ext

40

-24Vdc

1a

1c

Aut o/Manu
+24Vdc U/U

34 33

+U

-U

+I exc

44 45

-I exc
44 46

11 0V

Inf o Manu
Inf o Manu

CR17 to 20
PT2

3c, 3a
16a,17c
4c
4a

10

Q1

15a

PT1

K1
CR2

14a
CR3
14c
CR4

12c
CR6
8c
CR7

K7

+Vcc 1c
25a

DS1

K2
R13
R18

K3

24a

DS2

R12

13a
CR5

R14

16a

9c

CR21
to 24

C2

2c, 2a

CR5 to 10

TP3

CR1

2a
2c

11a

50
49

22 0V

44 42

44 43

CR11 to 16

R17

Cde cos

TP1

C1

48 47

8a
7c
9a
PT3

TP2

N de borne

17

8c

TP4
11c

10c

16

7a

23a

DS3

K4

R11

10

24c

DS4

K5

R10

11

22a

12

23c

13
14
15
16

11a
21a
7c
22c

DS5

K6

R9

CR8

DS6

+Vcc
+Vcc

21
22
23
24

Pot U
Pot U
Pot U
Cde par U

27
28
29

cos pot
cos pot
cos pot

30
31
32

KVAR pot
KVAR pot
KVAR pot

7a
3c
6c
3a

5c
8a
6a

12a
4c
5a

R8
R7

R6

17
23

R5

R4

19

20c
-Vcc 32a

21c

R3
R2

37
38
39

7c

Inf o Alarme
9a
Inf o Alarme
10a
Inf o Alarme

25 Mesure I exc 4a

}
N de borne

K8

R16

Connecteur male
DIN41612 32Pts

CR9
DS7

R15
25

21

Connecteur
HE10 26Pts

31a

17a
Connecteur male
DIN41612 64Pts

Liais on par conne cte ur HE10 26pts e t nappe

Liais on par conne cte ur LMI 10pts e t fils

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LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

GENERATOR I/O

ALTERNATE UR E / S
GENERATOR E / S

auto/manu

Cde cos

+U auto

-U auto

+I exc

PT1

-I exc

PT2
PT3

Alarm

R610 potentiometers position. For adjustments, refer to specific card technical manual

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LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

SUPPLY CARD

SUPPLY CARD
1) FUNCTIONAL

2) ADJUSTMENTS

- This card, from not regulated symetrical voltage,

generates +15Vdc and -15Vdc voltages with 0V common to
both named +Vcc for +15V and Vdd for -15V in the
following.
- The non rgulated voltages are first filtered (C01, C02),
pre-rgulated to 20dc with ballast stages Q01 et Q02 and
finally decreased to15V by means of RG01 et RG02
rgulators.

- None

3) INPUTS / OUTPUTS
- 2a, 2c
- 3a,3c
- 1a,1c
- 32a,32c
- 16a,17c

: Input +30Vdc not regulated

: Input -30Vdc not regulated
: Output +15Vdc regulated (Vcc)
: Output -15Vdc regulated (Vdd)
: Common electronic ground

- Its permanent current capability is 0,5 Amp on both

polarity.

MIMIC DIAGRAM OF ELECTRONIC SUPPLY CARD

+V not
re gulated

2a ,2 c

Filter

Pre -re gul

Regulator
+15Vdc

1c,1 a

+Vcc

LED
+15V

0v

16 a,17c

16 a,17c

0V

LED
-15V

-V not
re gulated

16

3a ,3 c

Filter

Pre -re gul

Regulator
-15Vdc

32 c,32a

-Vdd

16

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

SUPPLY CARD

BDX85C

Q01

2a,2c

RG01

TP1

1a,1c
7815
R03
3,3K

C03

R01 330

C05

0,33F 63v

C01

CR03
1N4007

CR01

1000F 40V

0,33F 63v

DS1

BZX85C20

16a,17c
TP2

R04
1000F 40V

3,3K

CR02

C02
R02 330

BZX85C20

C04
0,33F 63v

CR04

C06

1N4007

0,33F 63v

DS2

3a,3c

32a,32c
7915
Q02

RG02

TP3

ALIMENTATION
SUPPLY

FRONT VIEW
SUPPLY CARD

+15V

-15V

PT1
PT2
PT3

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LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

SENSING CARD

SENSING CARD
2) ADJUSTMENTS

1) FUNCTIONAL

- P1

- This card elaborates from the three phases voltage image

of the generator given by the "ALTERNATOR I/O" :
-A rectified, calibrated, filtered voltage Vm proportional to
the stator voltage of the generator. Vm could be affected by
droop depending of adjustment.
- A voltage function of the generator frequency, a part of
which gives the reference set point named Vref.
- Vref is a constant above the underfrequency threshold set
point (signaled by LED) and decreases below this threshold
following a function depending of the position of the strap
CV1:
- In fixed V/Hz mode
-In adjustable kVolt / Hz (see curve below)
Volt

Un

Mode Volt / Hz

- P2
- P3
- P4
- P5

: Reactive droop adjust for parallel operation

between equivalent machine.
: Vm adjust for nominal voltage. (9Vdc at Un)
: Underfrequency threshold adjust (normally
Fn 5%) signaled by LED.
: Underfrequency slope adjust ( k ) in kVolt / Hz
mode
: Voltage set point Vref for the nominal voltage
(9Vdc at Un and Fn)

3) INPUTS / OUTPUTS
- 7a, 8a, 8c : Voltage inputs image of the generator (3 x
21Vac between each and the GND)
- 9a
: Current input image of the generator stator
current (1Vac pour In)
- 1a,1c
: +15Vdc regulated (Vcc)
- 32a,32c : -15Vdc regulated (Vdd)
- 16a,17c : Common ground (GND or 0V)
- 11c
: Voltage output image of the generator (Vm)
9Vdc at Un
- 11a
: Voltage set point output (Vref) 9Vdc at Un
and Fn

Mode k x Volt / Hz
Fn - 5%

Fn

Hz

MIMIC DIAGRAM OF SENSING CARD

TI //

Um
Vm
Wm

9a

Reactive
droop

AC / DC

7a
8c

1c,1 a
16 a,17c
32 c,32a

AC / DC

8a

AC / DC
+Vcc

Filter

11 c

Vm

Threshold
U/F

0V
-Vdd
11 a

F -> kV
Voltage
set point

Vre f

LED
18

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LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

SENSING CARD
Principle diagram SENSING card

DETECTION
SENSING

Vref

P5
U/ kf

P4
U/f

P3

FRONT VIEW
SENSING CARD

Vm

P2
Statisme/Droop

P1
Sous vtesse
Underfrequency

19

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LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

PID, LIMIT CARD

PID, LIMIT CARD

1) FUNCTIONAL

2) ADJUSTMENTS

- This card, from Vm (machine voltage image), Vref

(voltage set point) and complementary informations given
in the following, elaborates the voltage command of the
power driver card, which is the field current set point.

- P1

- Three operating modes are possible, depending of

external informations :
- Solo operation or parallel
equivalent machines (1 Fonction)
( This is the normal mode)

operation

between

- Parallel operation with the mains with power factor

(COS) or KVAR regulation (2 Fonction)
( Only if COS / KVAR card is fitted)
- Operation in voltage equalization mode between
machine and mains before coupling (3 Fonction)
( Only if "MAINS I / O" card is fitted)
1F : Machine image Vmis compared with the sum of
Vref, Pext, etc voltages depending of used options and the
resultant voltage (error voltage ) feeds the PID.
2F : When cos cmd input is activated (+Vcc), the
machine voltage Vm is compared to the voltage given from
the cos/KVAR card and the result (error voltage ) feeds
the PID.
3F : When U/U cmd input is activated (+Vcc), the
machine voltage Vm is compared to the voltage given from
the "MAINS I / O" card and the result (error voltage ) feeds
the PID.
A compensation external input, given for specific
applications is added to the error voltage and the resultant
voltage is the real PID input. Each branch (P, I, D) of the
PID, independently adjustable from the others, set the time
constants of the AVR in regard to the generator. The
integrator branch can be short-circuited, for example when
starting-up.
These three outputs are added, limited to 10Vdc and
then give the field current set voltage of the "automatic
channel" which is the driver card input.
The minimum value of this signal can be limitated to avoid
total loss of excitation of the generator. In case of parallel
operation with the mains (cos/KVAR card), this limitation
is a function of the active power supply by the generator,
this information is given by the COS / KVAR card.

- P2
- P3
- P4
- P5
- P6
- P7
- P8

: Ceiling unlocked voltage threshold adjust

(normally 90% Un).
: Proportionnal branch gain adjust (large signal)
: Proportionnal branch gain adjust
: Integrative branch time constant adjust
: Derivative branch gain adjust
: Derivative branch time constant adjust
: Minimum field limitation adjust
: Minimum field limitation, active power correction
adjust

3) INPUTS / OUTPUTS
- 11a
- 13c
- 22c
- 21a
- 13a

- 19a
- 10a
- 14c
- 25c
- 24a
- 1a,1c
- 32a,32c
- 16a,17c
- 14a
- 15c

: Voltage reference set point input. Vref

: Added signal to voltage reference set point
input (option )
: Added signal to voltage reference set point
input (external voltage option )
: Added signal to voltage reference set point
input (external potentiometer option )
: Added signal to voltage reference set point
input
(differential
droop
option;
with
cos/KVAR card )
: Integrator short-circuit command input
: Mains image voltage input (3F) ( with "MAINS
I / O" card only)
: Cos error voltage input
(2F) (with
cos/KVAR card )
: Voltage equalization command input (3F)
(with "MAINS I / O" card only)
: Cos regulation command input (2F) (with
cos/KVAR card )
: +15Vdc regulated (Vcc)
: -15Vdc regulated (Vdd)
: Common electronic ground
: Minimum field limitation, active power
correction input
: Field current voltage control output "AUTO"
channel

A separate stage detect if the generator voltage is

below an adjustable value to unlock the normal field ceiling
voltage from 110% of nominal to 160% (adjustable).

20

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LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

PID, LIMIT CARD
MIMIC DIAGRAM PID, LIMIT CARD
Vre f
Vpot dig
Vstat
Cde U
Pe xt
Vre s
Cde U/U
Vm
Cos
Cde Cos
V Exte rn
Cct inte g
Vm -10%
Vm
Vre f

Icos

11 a
13 c

+
+

13 a

static
relay

+
+

22 c

static
relay

P
-

21 a
10 a
25 c

11 c
14 c

static
relay

24 a
12 c
19 a

9c

11 c
11 a

M in If

+
+
+

LED

10 V

If min
limit

14 a

AUTO output15 c

M in If

19 c

PID &
LIM Iexc

FRONT VIEW
PID CARD

P1

Vm
min

P3

P4

P5

LIM Iexc min

P7
Limit
Iexc min

21

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LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

PID, LIMIT CARD
Principle diagram PID, limit card

22

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LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

DRIVER CARD

DRIVER CARD
1) FUNCTIONAL

2) ADJUSTMENTS

This card controls from "AUTO" and "MANU" voltage

reference and some additional informations detailed in the
following, the exciter field current supply by the regulator
and the booster (if used).
- Three operating mode are possible, depending of external
informations :
- Normal mode with 110% ceiling of If nominal.
- Ceiling unlocked mode (160% minimum Ifield
nominal) depending of the command input from the PID
card with limited delay and alarm output in case of
sustained undervoltage.
- Maximum ceiling mode if the synchronisation voltage
desappears ( machine short-circuit) with limited (adjustable)
field current.
- The "AUTO" or "MANU" reference voltage depending
of the associated command input and also of the active
limitations, is compared to the field current measurement
and gives the error voltage which is after integration,
compared to a sawtooth feed by the synchronisation
voltage. The output of this stage is a variable duty cycle
signal which controls the power transistors throught
isolating optocouplors.

- P1
- P2
- P3
- P4

- This card can be supplied in three manners :

- From the general supply of the rack in normal operation
- Throught an isolated supply taken from the field voltage
during start-up or generator short-circuit. (Rack supply not
present)
- Directly from the field voltage for power transistor
command.
The permanent limitation (110% de Iexc nominal) can
be modified by the following conditions:
- Field ceiling unlocking on machine undervoltage
condition. It inccreases from 110% (normal operation) to a
minimum of 160% of the nominal field current during an
adjustable time delay and then go back to 110%. An alarm
is activated if this undervoltage is sustained afterward.
- Field ceiling unlocking on synchronisation voltage
abcence. It increases to the maximum given by the setting
of P7.
-Field ceiling limitation caused by power heatsink
overheating. On thermocontact action the ceiling is reduced
to a value given by the setting of P8.

- P5
- P6
- P7
- P8

: Integrator time constant adjust.

: Unlocked ceiling time delay adjust. (generally 5s)
: Alarm time delay adjust after ceiling unlock.
: Permanent ceiling value adjust
(generally 1,1If nominal)
: HALL sensor range adjust.
: Initial ramp-up adjust
: Maximum field current adjust (machine short-circuit
)
: Maximum fieeld current in case of heatsink
overheating.

3) INPUTS / OUTPUTS
Flat cable (BUS 64points)
- 15c
- 15a
- 25a

: If reference set point input "AUTO" channel

: If reference set point input "MANU" channel
: "AUTO / MANU" command input
(0V = "AUTO")
- 9c
: Unlocking ceiling command input
- 4a, 4c : Synchronisation voltage input
- 26c
: Heatsink thermocontact input
- 1a,1c
: +15Vdc regulated (Vcc)
- 32a,32c : -15Vdc regulated (Vdd)
- 16a,17c : Common ground (GND or 0V)
- 17a
: Field current measure output
- 19a
: End of ramp-up output signal
- 31a
: Alarm output

Card connector (8 points)

-1
-2
-3
-4
-5
-6
-7
-8

: Field voltage
: Main transistor drain
: Main transistor gate
: Booster transistor gate
: Power ground
: +Vcc HALL sensor
: -Vcc HALL sensor
: HALL sensor measure output

A separate circuit monitors the instantaneous current of the

power transistor and reduces immediatly the command
signal if its value increases above a fixed value. (Exciter or
wiring short-circuit protection ).

23

23

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

DRIVER CARD
MIMIC DIAGRAM DRIVER CARD
Su ppl y +/-1 5Vd c
32 a
16 a
1a
32 c
17 c
1c

Pow er block
connector
Auxil i ary su ppl y
(in su la te d)

-Vdd
Mea su re I
0 - V DC
Synch ro
Synch ro l oss
Inpu t MANU
Inpu t AUT O
Cmd Au to / Manu
Outpu t Cmd Ifi el d
Ce il i ng
un lo ck
Outpu t al arm
Li mi t If
Ramp e nd
Th ermoco ntact
he atsi nk

0V

Po wer V cc

-Vdd

HAL L se nso r

Po wer tran si stor

Cmd b ooste r IGBT

Cmd p ri ncip al IGBT

Po wer G ND

+V cc

17 a

Co nve rter I/U

Sh ort ci rcui t
mon itori ng

4a ,4 c Synch ro ni sa ti on
Syn ch ro l oss
18 c
15 c

1
+V cc

supp ly

sta ti c rel ay

PID

Opto

PWM

15 a
25 a
GND

16 c
9c

Ts

Ipl

HAL L se nso r
supp ly

Ra mp

Lim 1

31 a

Lim max

18 a
19 a
26 c

DRIVER

FRONT VIEW
DRIVER CARD

Iexc max

P7
Iexc lim

P4
T ramp

P6
T Iexc lim

P2
Vm min
Ramp end

24

24

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

DRIVER CARD
Principle diagram DRIVER card

25

25

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

COS KVAR OPTIONAL CARD

COS KVAR OPTIONAL CARD

1) FUNCTIONAL

2) ADJUSTMENTS

This option allows the parallel operation coupling with

the mains with P.F or KVAR regulation (also called 2F)
This card elaborates from generator current and
voltage informations, the following signals:
- An image of the reactive current of the generator
named (KVAR) used for KVAR regulation.
- An image of the phase shift between the voltage and
the current of the generator named () used for cos (PF)
regulation.
- An image of the active current of the generator
named (KW) used for compensate the minimum Ifield limit
of the PID card.

- P1
- P2
- P3
- P4
- P5
- P6
- P7

- The principle of measurement is to sample and hold

the instantaneous value of the current when the
instantaneous voltage reaches zero on positive slope.
- First the current image of the stator current is filtered
and used directly for KVAR measure. Then it is derivated
and used for KW measure. And then it is amplified to obtain
square waves and integrated to give a sawtooth used to
measure.
- The voltage image is phase-shifted to compensate the
phase shift of the current input filter and after amplification
is fed to a monostable which gives the pulse signal (about
100s) used by all the sample and hold circuits.
- KVAR and values are compared with an internal
and external (if used) setting and the difference is send to
the PID card as an error signal. An external contact control
an analog switch to select what information between KVAR
and will be regulated.
- Three informations (, , KVAR) can be used as
an alternative droop for solo operation.
- gives no droop at cos=1 and the voltage
decreases at lagging PF.
- gives no droop at the cos setting and the voltage
decreases at more lagging PF and opposite for more
leading PF.
- KVAR gives no droop at the KVAR value setting and
the voltage decreases with more KVAR and increases if
less.
- The selection between these is made by mean of
jumper (CAV) on the card. (internal)

26

: KVAR internal setting.

: PF (cos) internal setting.
: Voltage phase shifter (internal)
: PF (cos) gain setting
: KVAR gain setting.
: Diffrential droop setting
: Pulse width setting (internal)

- Jumper CAV : Selection of droop type

No
: Reactive droop adjusted by P1 (sensing card)
CAV1 : No droop for cos=1 and droop if lagging.
CAV2 : No droop for KVAR setting (P1), voltage decreases
if more KVAR (lagging) and opposite if less.
CAV3 : No droop for PF setting (P2), voltage decreases if
more lagging and opposite if less or leading.
Nota : If the droop is used from this card, potentiometer P1
of the sensing card must be set to zero.

3) INPUTS / OUTPUTS
Flat cable (BUS 64points)
- 8c
: Generator voltage image input
- 9a : Generator current image input
- 20a
: Command input "cos / KVAR" (0V = "cos")
- 21c
: External KVAR setting input
- 20c
: External cos setting input
- 1a,1c
: +15Vdc supply (Vcc)
- 32a,32c : -15Vdc supply (Vdd)
- 16a,17c : Common electronic ground
- 14c
: Error signal output to PID card
- 13a
: Droop signal output to sensing card
- 14a
: KW signal output to PID card
- 12a
: KVAR signal output
- 10c
: signal output

26

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

COS KVAR OPTIONAL CARD
MIMIC DIAGRAM COS KVAR CARD
Isi n
Co s

12 a

10 c
set p oi nt kV Ar
exte rn al
21 c

Vac
8c

Ph ase shi ft

set p oi nt co s
exte rn al
20 c
co mmand
Co s/KVAR
20 a

Mon osta ble

KVA R

TI //
9a

sampl e & hol d

Fi l te r

Isi n

Gai n
KVA R

Isi n

KVA R

14 c
Gai n
COS

x(fx) dt
1c,1 a

+V cc

d(fx)/d t

sampl e & hol d

2
3
1
CAV

-Vcc
32 c,32a
16 a, 1 7c

0V

sampl e & hol d

Icos

Co s
di ff re ntia l
droo p

13 a

Icos
14 a

COS, KVAR

KVAR

P1

FRONT VIEW
COS KVAR CARD

Gain kvar

P5
Cos

P2
Gain cos

P4
Statisme D

P6

27

27

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

COS KVAR OPTIONAL CARD
Principle diagram COS / KVAR card

28

28

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

GENERATOR / MAINS I/O (3F) OPTIONAL CARD

GENERATOR / MAINS I/O (3F) OPTIONAL CARD

1) FUNCTIONAL
This option allows the automatic matching of the mains &
generator voltage during synchronizing (also called 3F)
- This unit is mainly an interface between external signals
and low power electronics.
- It is composed by :
- The adaptation three phases transformer between input
voltages (generator (1F,2F) and mains (3Fonly) and
measurement circuits.
- The burden resistor of parallel CT.
- The adaptation transformer between input voltage and low
power electronic supplies.

- The interface input relays between command / control

terminals and internal circuits.
- The interface between 64pts BUS and the analogic input
/ output terminals

2) ADJUSTMENTS
- Voltage matching adjustment (P1) (3Fonly)

3) INPUT / OUTPUT
- See following table

INPUT
TERMINAL

Connector
32 PTS

Type
I/O

Interface

Connector
26 PTS

Connector
BUS 64 PTS

12
13
14

15c
13c
11c

measure
measure
measure

transfo tri TP4

transfo tri TP4
transfo tri TP4

13
17
21

5a
6c
6a

51
52
54
55
56
57
58
59
60

1a
3a
2a
4a
5a
6a
7a
8a
9a

signal
signal
reserve
reserve
reserve
reserve
reserve
reserve
reserve

direct
direct

3
5
7
2
4
6
8
10
12

15a
27c
27a
28c
28a
29c
29a
30c
30a

36

4c
2c
3c
2c

Cmd input
Cmd input
Cmd input
Cmd input

relay
relay
relay
relay

1
9
14
9

25c
1c
20a
1c

10c
9c

Ground
thermostat

direct
direct

25
26

16a, 17c
26c

53

VOLTAGE INPUTS :
Reference
C5 195 0220
C5 195 0222
C5 195 0210

29

Functions
3F
3F
2F

Mains sensing voltage

100V to 120V 50/60Hz
400V to 450V 50/60Hz
none

29

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

GENERATOR / MAINS I/O (3F) OPTIONAL CARD

12

U rseau

15c

13

N
13
Bornier

V rseau

11c

17

W rseau

7c

14

TP4

5a
6c

21
25

6a
16a, 17c
+Vcc 1c
AC
DC

L1

L2

10a

L3

-Vcc 32a

35 36
Bornier

Cos /Kv ar

Cde U/U

2c 16a
Reserv e
Vers 32pts J1
alternateur I /O

Therm os tat
Therm os tat
51 Cmd I ex cit
52 Pot MANU
54
Reserv e
55
Reserv e
56
Reserv e
57
Reserv e
58
Reserv e
59
60

Reserv e
Reserv e

R27

4c

K1

2c
5c

9
1
R26

CR15

10c
9c

R31

CR17

7a
8a
9a

25c

31c

25

1a
3a
2a
4a
5a
6a

20a

K3
11

Connecteur male
DIN41612 32Pts

30

K2
14

+12Vdc U/U

N
Bornier

CR16

CAVALIERS

48 53
Bornier

3c

26
3
5
7
2
4
6
8
10
12

Connecteur
HE10 26Pts

26c
15a
27c
27a
28c
28a
29c
29a
30c
30a
Connecteur
41612 64Pts

30

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

GENERATOR / MAINS I/O (3F) OPTIONAL CARD
AC / DC converter schematic diagram

11
MA 1/1

R02

R22

4
R07

C R14

16a

MA 1/2
C R15

17c

C R1
1

C01

PT7
C R2
7

R14

R10

9
MA 2/3

5
10

0V

1c,1a
32c,32a

+Vcc

MA 1/3

-Vcc R01
R23

R03

PT4
PT5

PT6

R13

0V

C R16
R04

R05

10

MA 1/4

MA 2/1
3

C R18

0V

MA 2/2

10a

Ur

12
R18

C R4
14
+V cc
C R13

R20

C R5
1

L1

4
R09

C R19

14

0V

PT8

PT9

R06

TP4

C05

R15

R12

R24

MA 2/4

P01

12

11

C02
13

R11

0V
2

R16
R17

R25

R21

R08

13

C R17

C R3
8

PT10

Q01

C R6
7

5
R19

U V W

0V

RESEAU E/ S
MAINS I /O
Reseau

P01

FRONT VIEW
MAINS I/O CARD

PT1
PT2
PT3
PT4
PT5
PT6
PT7

S1
Cos / Kvar
U/U

31

31

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

Digital pot U / P.F OPTIONAL CARD

Digital pot U / P.F OPTIONAL CARD

1) FUNCTIONAL

2) ADJUSTMENTS

This
card
replace
two
conventional
motorized
potentiometers:
- One for the remote voltage setting.
- One for power factor or reactive current setting.

- P1
- P2
- P3
- SW1
- SW2

- Switch between the two modes is made by the external

P.F regulation order (terminals 33,34 on R630 & 30,31 on
R610) and switch between P.F and KVAR setting is made
by the external order (terminals 48,53 on R630 & 37,38 on
R610)
- Each last position is memorized when the control is
switched or when the machine is stopped.
- Jumps (SW1 and SW2) allow the choice between unipolar
or bipolar voltage output and the range is adjusted by
means of potentiometers P02 and P03.
- Jumps SW3 and SW4 must be open for normal operation
and are only used for special applications.
- Speed of all adjustments is controled by potentiometer
P01.
- Two LED's (L1,L2) indicate the command orders + or and four other LED's (L3,L4 and L5,L6) indicates the
maximum and minimum position of voltage and P.F
settings

: Clock speed (total range time)

: Voltage range value
: P.F or KVAR range value
: Voltage range polarity (0/+ or +/-)
: P.F or KVAR range polarity (0/+ or +/-)

3) INPUTS / OUTPUTS
Flat cable (BUS 64points)
- 24c
- 23a
- 16c
- 15c
- 24a
- 20a
- 13c
- 20c,21c
- 30a
- 1a,1c
- 32a,32c
- 16a,17c

: Cmd lower
: Cmd upper
: If reference set point input
: If reference set point input "AUTO" channel
: External P.F regulation order
: External P.F or KVAR regulation order
: Voltage setting output to PID card
: P.F or KVAR setting output to P.F card
: Maximum position of settings
: +15Vdc regulated (Vcc)
: -15Vdc regulated (Vdd)
: Common ground (GND or 0V)

- NOTE: When this card fitted, the internal voltage

setting (P05 on sensing card) must be used to give the
center position of the range (if bipolar range) or the
minimum setting in case of unipolar range (idem for
P.F and Kvar internal setting on P.F card). An external
setting potentiometer must not be used , the settings
are made only by mean of push-buttons on terminals
42,43,44 with R630 and on 35,36,37 with R610.

32

32

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

Digital pot U / P.F OPTIONAL CARD
Digital U / P.F. Card Mimic Diagram

UP

Cmd +

INC

DOWN

Cmd -

Logic

24 c

static
relay

M in
M ax Pos

Digital
pot U

30 a

CS

0V

Cmd P.F

M ax

U/D

23 a

24 a
-Vre f

SW1
SW2

U/D

Cloc k

P01
Spe e d

INC

CS

M ax
Digital
pot P.F /
KVAR

M in

U r ange
+
P.F / Kv ar
range

static
relay

P.F Output
20 c
Kv ar Output
Kv ar Cmd

21 c
20 a

DIGITAL
SETTINGS

HAUT
UP
BAS
DOW N

FRONT VIEW

MA X

Digital Pot U / P.F.

Volt age
MIN
MA X

Cos - Kvar
MIN

P1
SPEED

33

33

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

Digital pot U / P.F OPTIONAL CARD
Principle diagram Digital Pot U / P.F / KVAR

34

34

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

Manual mode 1 OPTIONAL CARD

Manual mode 1 OPTIONAL CARD

1) FUNCTIONAL

2) ADJUSTMENTS

This card elaborates from internal setting (PO2) and

external setting informations, the Ifield command signal
given to "MANU" channel of the driver card.
- The Ifield output signal is limited or reduced if the
generator voltage exceeds the limitation value sets by the
potentiometer P01 (trip of the main breaker on load for
example ).
- This case of operation is indicated by the LED "LIMIT"
and the Ifield setting must be decreased to a point under
control.

- P1
- P2
- P3
- P4

- On MANU operation, the difference between MANU

output and AUTO channel output gives a compensation
signal which is used to compensate the PID to have always
the MANU and AUTO channels outputs identical. With this
circuit a smooth switching between MANU to AUTO is
possible and operation will go back to the AUTO channel
own settings.
- The ceiling can be unlocked on this operation, that is why
it can be necessary to wait some seconds after the
switching to return on MANU operation.

: Voltage limitation setting

: Internal Ifield value setting
: PID compensation gain setting
: Internal compensation setting

3) INPUTS / OUTPUTS
Flat cable (BUS 64points)
- 4c

: 24Vac input image of the generator from

"generator I/O" card
- 25a
: "AUTO / MANU" command input
(0V = "AUTO")
- 16c
: If reference set point input
- 15c
: If reference set point input "AUTO" channel
- 27c
: External Ifield setting input
- 1a,1c
: +15Vdc regulated (Vcc)
- 32a,32c : -15Vdc regulated (Vdd)
- 16a,17c : Common ground (GND or 0V)
- 15a
: If set point output "MANU" channel
- 12c
: PID compensation output
- 9c
: Ceiling locked output

- On AUTO operation, these two channels are also

monitored and the difference is indicated by three LEDs.
- HIGH says that MANU channel is higher than AUTO
- LOW says that MANU channel is lower than AUTO
- OK says that MANU and AUTO channels are
identical and smooth AUTO ---> MANU switching is
possible.

-NOTE:
If a I field digital potentiometer is used, the internal
setting (P02) must be set to 0 or under the no load field
value and an external setting potentiometer must not
be used. In that case the setting is made only by mean
of push-buttons on terminals 44,45,46

35

35

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

Manual mode 1 OPTIONAL CARD
MANUAL MODE CARD MIMIC DIAGRAM

24Vac

4c

AC / DC

Filte r

Ampli PI
+

Manu out
15 a

+
Exte rnal Cmd
27 c

Voltage
Limitation

Se t point
Ifie ld
Limitation

Inte gr al
short cmd

9c

ET

Se t point
too hight

Cmd
auto/manu
Corr ec t
PID
Cmd Ie xc
Auto out

25 a

12 c

relais
statique
16 c
15 c

Manu out

Auto out

Gain

Se t point
too low

ET

Se t point OK

MANUAL
MODE

FRONT VIEW
Manual Mode 1

LIMIT
HAUT
HIGH
LOW
BAS
OK

P3
Seuil

P2
Iexc

P1
Gain

36

36

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

Manual mode 1 OPTIONAL CARD
Principle diagram Manual mode 1

37

37

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

Pot Digital Ifield CARD(Option)

CARTE Digital Pot Iexc CARD (Option)

1) FUNCTIONAL

2) ADJUSTMENTS

- This card replace one conventional motorized

potentiometer in MANU mode and sets the MANU
channel output always equal to the AUTO one to allow
the smooth switching between the AUTO and
MANU operationr at any load (follower in AUTO
mode).

- Switch between the two modes is made by the external

"AUTO/MANU" order (terminals 47, 48).
- Jump SW1 allows the choice between voltage output
taken from U/F control of the sensing card or from a 5V
fixed reference and the range is adjusted by means of
potentiometer P03.
- Jumps SW3 and SW4 must be open for normal operation
and closed for follower operation.
- Speed of the adjustment is controlled by potentiometer
P01 in manual setting and by P02 in follower operation.
P02 acts as a delay between an AUTO output variation
and the MANU output response.

P1 : clock speed (time delay in follower mode)

P2 : clock speed (range time in "MANU" mode)
P3 : I filed range value
SW1 : fixed voltage range or U/f monitored
SW3/4 : Normal (open) or follower (closed) operation

3) INPUTS / OUTPUTS
Flat cable (BUS 64 points)
-

23c
: Cmd lower
22a
: Cmd upper
25a
: Cmd "AUTO / MANU"
11a
: U/f voltage reference
16c
: If reference set point input
15a
: If reference set point input "MANU"
channel
27c
: If setting output to Manual mode card
30a
: maximum position of settings
1a,1c : +15Vdc regulated (Vcc)
32a,32c : -15Vdc regulated (Vdd)
16a,17c: Common ground (GND or 0V)

- Two LEDs (L1, L2) indicate the command orders + or

and the two other LEDs (L3, L4) indicate the maximum and
minimum position of I field settings.
NOTE :
When this card is fitted, the internal I field setting (P02
of manual mode card) must be set to 0 or under the no
load field value and an external setting potentiometer
must not be used.
The I field setting is made only by mean of push
buttons on AVR terminals 44,45,46.

38

38

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

Pot Digital Ifield CARD(Option)
I field digital pot MIMIC DIAGRAM
UP

Cm d I+

U/D

22a

INC

DOWN

Cm d I-

Logic
CS

23c

Out

Digital
pot 2
In

Max Pos
SW 4

SW 3

30a
+5V
Vref

P01
Follow e r Spe e ds tatic

SW 1

U/D

relay

INC

Clock

In

Digital
pot 1

Max
Min

Out
CS

P02
Manu Spe e d
Cm d
Auto/Manu

25a

Ie xc r ange
16c

Sm anu

Ie xc s e t Output

+
15a

Cm d Ifie ld

27c

Iexc DIGITA L
SETTING

HAUT
UP
BAS
DOW N

FRONT VIEW

MA X

Digital Pot I field

Iexc
MIN

P1
SPEED

39

39

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

Pot Digital Ifield CARD(Option)
Principal diagram I field digital potentiometer

-I

L1

R8

+Vcc

32 c,32 a

-Vcc

-Vcc

23 c

R10

22 a

R11

REG1

+Vcc

R12

R3
R1

T1

MN2

HIGHT
HAUT

C2
L2

R13

R4

CR5

R6

+Vcc
SW3

R7

AND

CR3

SW4

MN6

P01

R30
R22

AND

R16

16c
MN2

16c
Cde Iexc R17

-Vcc

R23

+Vcc

MN2
R18

15a
Smanu

R20

R21

R25

0V

R42

HR

AND
S2

7
4
5

AND

U/D
S4

U/D
R26

AND

C3

MN7

MN1

POT1

+5V

S4
1
INC 4 6

AND

3
8

11a
R34

R35

0V

SW1

+5V

3
CR06

R1

MN8

Vref
R33

CS

AND

P2

1
MN9

C08

MN1

R31
R32

R36

0V

P03

3 - P2

+Vcc

MAX
L3

CR9

-Vcc

CR8

30 c

R40

Range
+/-5V + /-10V

Pot Manu
27 c

R51

pot end

CR7
R46

R43

Cde A/M
25a

S1

HR

Cde Iexc R19

+5V

MN7

AND

8
Smanu
15a

INC 1

0V

R48

R24

+Vcc

AND

0V

CS

0V

64
2

POT2

AND

CR2

-Vcc

0V

MN6

T2
CR4

U/D

+5V

R15

MN2

0V
+5V

7805
C7

R5
CR1

R2

+Vcc

+5V

R14

R9

+I

DO WN
BAS

C1

1c,1a

R52
R49

L4

MIN

5 - P2
6 - P2

40

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LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

Mains P.F Regulation OPTIONAL CARD

Mains P.F Regulation OPTIONAL CARD

1) DESCRIPTION
This card is used when the P.F or KVAR regulation is
wanted not at the generator terminals but at the mains
input. For this a P.F or KVAR sensor with 4-20mA output is
necessary and it must be located at the place where the
regulation must be made.

2) FUNCTIONAL
This card elaborates from setting informations and 420mA signal image of P.F (or KVAR) of the mains, the
errorvoltage dending to the PID of the PID card.
- The error signal have an ajustable gain and can be
inversed depending of the 4-20mA sensor output.
- This kind of operation is indicated by the LED "L3" and
by a contact (potential free) on the front connector.
- This operation is selected by mean of a contact on front
connectort and will be active on coupling when contact
between terminals 33,34 of main terminals will be closed. If
the contact
on front connector remains open, the
regulation (P.For KVAR) will be made at the generator
output, if it is closed, this is the 4-20mA information wich is
regulate function of the internal settings (P2 or channel 2
4-20mA) or/and external by the front connector.
-If during operation, the measuring 4-20mA signal
deseappears, control is automatically return to regulation
on the generator output side and this failure is indicated by
LED L1 ou L2 and by a contact on front connector .
- A second channel can be used as set point of the first
channel or as a remote adjustment of voltage, P.F or KVAR
on generator side. As on channel 1 if the 4-20mA
deseappears, output is inhibited and indicated by LED L2.
- A field current limitation is given, active when a contact
(front connector) is closed and indicated by LED L4. The
limitatio is adjusted by P7 (Limit 2 set) and can be set
between a maximum value preset by P7 on driver card and
a minimum value preset by P8 on driver card.
- A signaling contact on the front connector gives (if they
are used) the indication that one or more of the digital
potentiometers are at maximum position .

3) ADJUSTMENTS
Potentiometers
- P1
- P2
- P3
- P4
- P5
- P6
- P7

: Channel 1 range adjustment

: Reference set point channel 1
: Gain channel 1
: Channel 2 range adjustment
: Reference set point channel 2
: Gain channel 2
: Limit 2l adjustment

Jumpers
- CV1 A
- CV1 B
- CV2 A

41

: Channel 1 used
: Channel 1 not used
: Channel 1 used

- CV2 B
- CV3 A
- CV3 B
- CV4 A
- CV4 B
- CV5 A
- CV5 B
- CV5 C
- CV5 D
- CV6 A
- CV6 B
- CV6 C
- CV6 D
- CV6 E

: Channel 2 not used

: Non inverting error channel 1
: Inverting error channel 1
: Non inverting error channel 2
: Inverting error channel 2
: Channel 1 in 4-20mA regulation channel 1
: Channel 1 in voltage setting
: Channel 1 in generator P.F setting
: Channel 1 in generator KVAR setting
: Channel 2 in 4-20mA regulation channel 2
: Channel 2 in voltage setting
: Channel 2 in generator P.F setting
: Channel 2 in generator KVAR setting
: Channel 2 in channel 1 setting

4) INPUTS / OUTPUTS
Flat cable (BUS 64points)
- 12c
: Error output to PID
- 21a
: Output to voltage setting
- 20c
: Output to generator P.F setting
- 21c
: Output to generator KVAR setting
- 30a, c : Digital pot at maximum position
- 1a,1c
: Supply +15Vdc regulated (Vcc)
- 32a,32c : Supply -15Vdc regulated (Vdd)
- 16a,17c: Common ground
- 23a
: Cmd + U or + P.F
- 24c
: Cmd - U or - P.F
- 14c
: Output of generator side P.F card
- 24a
: P.F regulation order
- 26c
: Limitation 2 output to driver card

Front connector (DB25 points)

- 13
- 25
- 20
- 12
- 24
- 11
- 23
- 20
- 10
- 22
-9
- 21
-8
-3
- 15
-2
- 7,19
- 14,1

: + 4-20mA input channel 1

: 4-20mA output channel 1
: 12V to external setting potentiometer ch 1
: External setting potentiometer cursor ch 1
: Ground to external setting potentiometer
: + 4-20mA input channel 2
: 4-20mA output channel 2
: 12V to external setting potentiometer (ch 2)
: External setting potentiometer cursor ch 2
: Ground to external setting potentiomete
: 4-20mA failure (NO)
: 4-20mA failure (NF)
: 4-20mA failure (Commun)
: Digital pot at max position (NO)
: Digital pot at max position (NF)
: Digital pot at max position (Common)
: Contact regulation ch 1 active (mains P.F)
: Contact limitation 2 active

LED
- L1, L2
- L3
- L4
-

: 4-20mA failure channel 1 or 2

: Channel 1 active
: Ifield limitation 2 active

41

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

Mains P.F Regulation OPTIONAL CARD
MAINS P.F REGULATION CARD MIMIC DIAGRAM
Conne ctor
DB 25 points

Conne ctor
64 points

13

20

+1 2V

24

0V

4 -20mA
/ 0-10V

23

10Hz
Filter

Exter nal se tting 2

FRONT CONNECTOR I / O

20

0V

Ope n : reg
ge nerator
P.F
Clos ed : reg
mains P.F
Ifield
Limit
2

Corr PID
12 c
R

CV3

CV6

Gain

M A9

A
B

A
B
C

CV4

Corr PID
12 c
R
Re f U
21 a
Re f P.F

20 c

Re f Kv a r 21 c

D
E

CV2

L2

K1

K1

16 a, 1 7c

0V

+V cc
-Vcc

15

Pot dig
at max
position

Int se tting
channe l 2

CV1

L1

21

4 - 20mA
fa ilure

A
B

CV5

+1 2V

22

4 - 20mA
fa ilure

10

Pot e xt
Re f 2

Int se tting
channe l 1

11

Chan 2
4 -20mA

K5

Exter nal se tting 1

12

Pot e xt
Re f 1

Gain

10Hz
Filter

4 -20mA
/ 0-10V

25

K2

K2

30 a

Adapt
K5

K1

24 c
14 c

Limitation
Ifie ld 2

+V cc

14

30 c

23 a

L3
19

1c,1 a
32 c,32a

0V

24 a
0V

26 c

L4
1

aux I / O

FRONT VIEW
MAINS P.F REG

MA IN
P .F O N

25

13

4 -20 mA
1
OFF
2
Limit 2
14 1
ON

42

P2

Main
P .F
set

P5

Ref 2
set

P7

Limit
2
set

42

REAR FLAT CABLE I / O

Chan 1
4 -20mA

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

Mains P.F Regulation OPTIONAL CARD
Principle diagram mains P.F. reg card

43

43

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

LIMIT I Stator OPTIONAL CARD

LIMIT I Stator OPTIONAL CARD

1) FUNCTIONAL

2) ADJUSTMENTS

- A voltage, image of the stator current of the machine, fed

from the "ALTERNATOR I / O" card is rectified, filtered and
compared to a reference voltage. The error signal gives a
voltage correction which is added to the main PID input to
maintain the stator current equal to the adjusted value.
- The reference voltage is applied with an initial ramp
ajustable from 0,5 to about 4s.
- A front LED signals stator current limitation operation.

- P1
- P2
- P3

- When this card is used for soft-start operation, the AVR

power transformer must be fed from a separate source
during the start operation and can be switched on the
generator output when the voltage have reached the
nominal value. The switching must be as fast as possible
(by relay , not by manual switch)

: Stator current limit adjust. (about 2In to 4In )

: Ramp-up time adjust. (0,5 4s environ)
: Output signal gain

3) INPUTS /OUTPUTS
- 9a
- 1a,1c
- 32a,32c
- 16a,17c
- 12c

: Stator current image input (1Vac for In)

: +15Vdc regulated (Vcc)
: -15Vdc regulated (Vdd)
: Common ground (GND or 0V)
: Voltage correction output to PID.

MIMIC DIAGRAM I stator limit card

TI //

9a

1c,1 a
16 a,17c
32 c,32a

Ref
Istator

AC / DC

Filter

+Vcc
0V

-Vdd

GAIN

+
RAMP

12 c

Ampli PI

Limitation

LED

44

44

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

LIMIT I Stator OPTIONAL CARD

C01

9a R01

R04
R02

9
MA 1/3

MA 1/1
8

R05

10

C R01

11

4
R06

R09

MA 1/2

C03
13
MA 1/4

P01

C R4

C02

14

12

R08

C R02

R10
R11

R07

R03

C R3

R12

0V

0V

16a
17c
1a,1c
32a,32c

(P ositif = desexcitation

0V

12c

+V cc

+Vcc
-Vcc

R27

R23

L1
C04

-Vcc

R19

C06

Q01

R25
R14

11

MA 2/1
P02

R16

R17

R15

6
MA 2/2

4
R18

R13

C R06

C R05

C05

R22
P03

R20

C R07

R21

MA 2/3

C R08

10
R24

R26

0V

LIMIT
I STATOR

LIMIT

FRONT VIEW
Limit I stator card
P1
SEUIL

P2
Ramp

P3

45

GA IN

45

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

START - UP

START - UP
- E02 must short-circuit the booster output (if used)
(terminals 7 and 8 of AVR) and is closed for de-energizing.

CAUTION
Never energize the AVR when the driver card
is removed. An overvoltage can appear and
the power transistor can be damaged

1) STARTING WITH MANUAL MODE CARD

- For initial start-up, the best is to use the manual mode for
testing the sensing wires between the generator and the
AVR.
- For this it is necessary to have a manual mode card
plugged in the AVR. If not, see directly 2.
- Short circuit terminals 47 & 48 AVR terminal block).
- Set the potentiometer P2 on manual card maximum CCW,
start the prime mover up to the nominal speed.
- Turn slowly the potentiometer CW to obtain the nominal
voltage.
- Check the presence and the value of the three phases at
the AVR terminal block ( terminals 1, 2, 3 )

4) ADJUSTMENTS
- Refer also to card descriptions.
- The AVR is normally preset in factory.
- The nominal voltage can be set by Vref (P5) on sensing
card. Fine adjustment can be made by an external voltage
potentiometer (10K), (terminals 21,22,23)
-If an adjustment must be moved, note carefully
original setting for resetting in case of problems.

the

- If the strap V/Hz of sensing card is on kV/Hz position, the

original setting is V/Hz and can be changed between V/Hz
and 2V/Hz by potentiometer P4.
-The stability is adjusted with the machine in factory . If
necessary, the response time can be changed by the
setting of potentiometer P4 of PID card.
- Other settings are difficult to adjust without specific
electronics equipments. It is better to not change them.

5) FIELD FLASHING

- Check that the voltage between terminal 25 and 26 of the

AVR terminal block is about one volt.

- Generally, field flashing is not necessary, but in some

cases like long stop time or fault trip, it can be possible that
the voltage does not appear naturally.
In this case, connect a 12Vdc to 24Vdc voltage source to
the terminals 4 and 8 of AVR terminal block, + to 4 for a
short time and remove it when the voltage increases.

- If yes, remove the strap between terminals 47 & 48 of

AVR terminal block.

6) PARALLEL OPERATION(1F)

- The voltage must reach the nominal value.

- The generator voltages must be as equal as possible.

- Go to 3

- Same for the droop. If it is not possible to measure it, set

the potentiometers P1 of the sensing cards all in the same
position. (middle set for example). If the droop setting is
made from cos/KVAR card (when used), see notice NT
1950080.

- Set the voltage to 5% above the nominal voltage.

2) STARTING WITHOUT MANUAL MODE CARD

- start the prime mover up to the nominal speed..
- If the voltage does not appear, check wires between AVR
and the generator field (terminals 5 and 6 of AVR),and the
also the wires between AVR and power transformer
(terminals 18 and 19 of AVR). Check also the fuse inside
the terminal 19 of AVR terminal block.
- If the voltage is too hight, check that the sensing voltages
at the terminals 1, 2, 3 of the AVR terminal block, and the
auxiliary voltage at terminals 16 & 17 of AVR, are present.
- Adjust the nominal voltage with Vref (P5) of the sensing
card for the middle position of the external voltage
potentiometer (if used).

- The reactive currents (KVAR) must be shared, immediatly

after coupling, even the KW are not shared.
- If, immediatly after coupling, the current increases
abnormally, check if the parallel CT wires are not reversed.
( 9 et 10 of AVR terminal block)
- If the coupling is OK but if when the load increases, the
cos or the current have an abnormal value, check that
the sensing phases at the input of the AVR are right
connected. (U, V, W respectively to the terminals 1, 2, 3 if
clockwise rotation or W, V, U, if counter clockwise rotation)

3) DE-ENERGIZING (optional)
- External contacts E01 and E02 must be used.
- E01 must be serie with terminal 19 of AVR (power input)
and is opened for de-energizing.

46

46

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

START - UP
7) PARALLEL WITH THE MAINS (2F)

9) MANUAL OPERATION (if used)

- The generator and mains voltages must be as equal as

possible. (see GENERATOR/ MAIN I/O card manual). The
contact between terminals 33, 34 of AVR terminal block
must be closed at the same time as the coupling and
will remain closed as long as the generator is connected to
the mains.

-If a manual mode card is used, it is possible to control

directly the field current of the generator.
- In automatic mode, adjust the potentiometer P2 on
manual mode card to have the LEDs "HIGHT" and "LOW"
off and the LED OK ligthing. At this time the manual setting
is equal to the automatic channel control.

It will be open when parallel between generators.

- short circuit the terminals 47,48 of the AVR terminal block

gives control to the manual channel and the field current is
adjusted by potentiometer P2 and/or by an external optional
potentiometer (10k 1W) connected to the terminals
30,52,23 of the AVR terminal block cursor on 52 and hot
point on 30.

- If, immediatly after coupling, the current increases

abnormally, check if the parallel CT wires are not reversed.
( 9 et 10 of AVR terminal block)
- If the coupling is OK but if when the load increases, the
cos or the current have an abnormal value, check that
the sensing phases at the input of the AVR are right
connected. (U, V, W respectively to the terminals 1, 2, 3 if
clockwise rotation or W, V, U, if counter clockwise rotation)
- The PF value is normally factory set to 0.9 . It can be
adjust by mean of potentiometer P2 on cos/KVAR card or
by mean of an external potentiometer (10K-1W)
connected to AVR terminal block (27, 28, 29)
- If the KVAR regulation is required terminals 48 and 53
must be short-circuited and the KVAR can be set by mean
of potentiometer P1 on cos/KVAR card or by mean of an
external potentiometer (10K-1W) connected to AVR
terminal block (30,31,32)

- This mode can be used when initial start-up of the

generator, to make test after problems or when operating
with the mains. It cannot be used when solo operation
because it is not possible to follow the load variations.
- When coupling with the mains on load, if trip of the
generator occurs, an overvoltage may occurs due to the
fact that the field current setting is too hight regarding the
load of the generator. On this case, an internal circuit of the
card decreases the field current to limit the overvoltage
approximatively to 110% of nominal, the voltage in this
case can be unstable but protect faster the equipments.
LED "LIMIT" on front of the card will light. The setting of
field current must be reset manually to the no load value
and the LED "LIMIT" will switch off.

-For droop setting, see notice NT 1950080.

8) VOLTAGE EQUALISATION (3F)

- The following procedure must be made one time to take
account of the mains transformer primary/secondary ratio.
- At no load and mains voltage present at terminals
12,13,14 of the AVR terminal block.
- Short circuit terminals 35,36 of the AVR terminal block
- Adjust P1 of MAIN I/O card to have generator and mains
voltage as equal as possible.
- Remove the strap between terminals 35,36 of the AVR
terminal block.
- The initial setting is made.
In normal operation the contact between terminals 35,36 of
the AVR terminal block must be closed with synchronizer
operation and can be opened after coupling.

47

47

LEROY-SOMER

Installation and Maintenance

4009 en 01.2006 / a

AVR MODEL R630

MOTEURS LEROY-SOMER 16015 ANGOULEME CEDEX-FRANCE

48

48

LEROY SOMER

Service & Operating Manual

ALTERNATORS
Drawings

SECTION 5

Drawings
Dedicated manuals for specific equipement

SECTION 5

LEROY SOMER

Service and Operating Manual

Generator unit
1. DRAWINGS
1.1 Find there the listing of the attached drawings :
Main dimensions
Rotating part
Terminal box
Electrical nomenclature

EN 060 007 - 0100

P1 060 0005
BO 027 1782 - 1848
S4 601721

SECTION 5